PLM114 Basic Data for Ma Nu Factoring

PLM114 Basic Data for Manufacturing and Product Management mySAP Product Lifecycle Management

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Participant Handbook Course Version: 2006 Q2 Course Duration: 5 Day(s) Material Number: 50079412

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

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Copyright Copyright © 2006 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.

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

About This Handbook

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

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

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

Unit 1: Overview of Master Data for Product Management and Manufacturing .............................................................. 1

Unit 2: Organizational Data in Supply Chain Management..... 21

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Unit 3: Material Masters ................................................ 39

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Overview of the Bill of Material .....................................132 Managing Bills of Material ..........................................147 BOM Reporting.......................................................178 Configuration of the Bill of Material ................................189

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Unit 4: Bills of Material ................................................ 131

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Modeling Manufacturing ............................................215 Basic Work Center Data and Defaults ............................221 Capacities in the Work Center .....................................238 Integrating Costing with the Work Center.........................250 Configuring the Work Center ......................................253

Unit 6: Task Lists........................................................ 281 Overview of the Task List ...........................................282 Creating a Routing and Material Assignment ....................296 Suboperations and User-Defined Fields ..........................307 Reporting and Mass Changes......................................315

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Unit 5: Modeling the Manufacturing Process .................... 213

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Overview of the Material Master .................................... 41 Creating a Material Master .......................................... 47 Classification of the Material Master ............................... 72 Managing the Material Master....................................... 87 Configuration of the Material Master ..............................104

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Plants ................................................................... 22 Storage Locations..................................................... 27 MRP Areas............................................................. 32

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Types of Data in SAP ERP ............................................2 Use of Organizational Data and Master Data in Production.......7

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Configuring the Routing .............................................327

Unit 7: Advanced Bill of Material Functions ...................... 339 Phantom Assemblies ................................................341 Co-Products and By-Products......................................345 Discontinuation and Substitute Parts in the Bill of Material.....353 Multiple and Variant BOMS .........................................369 Mass Changes and the Product Structure Browser .............393

Unit 8: Advanced Routing Functions .............................. 405

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Index ....................................................................... 531

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Structure of the Engineering Workbench .........................494 Navigating in the Engineering Workbench .......................500 Engineering Workbench Work Areas..............................516

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Unit 9: Engineering Workbench ..................................... 493

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Modeling Complex and Flexible Manufacturing Processes ....407 Modeling Alternative Manufacturing Processes..................418 Reference Operation Sets ..........................................431 Lead Time Scheduling and Material Master Updates ...........441 Time Components, Reduction Possibilities in the Routing .....450 Trigger Points in the Routing .......................................464 Scrap and Its Effects ................................................468 Production Resources/Tools........................................480

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Course Overview This course will educate participants on how master data and organizational data is maintained in SAP ERP. Participants will learn how to create, manage, report and configure the master data objects that are relevant to the production planning process. This will include:

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Plants Storage Locations Material Masters Bills of Materials Work Centers Task Lists and Routings

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This course is intended for the following audiences:

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Project team members and employees responsible for configuring, creating, and maintaining the follow master data objects in SAP

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Plants Storage Locations Material Masters Bills of Material Work Centers Task List/Routings

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Course Prerequisites

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Required Knowledge •

Basic understanding of Supply Chain Management in SAP ERP

Recommended Knowledge •

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Basic understanding of master data requirements in a production planning and execution environment

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Target Audience

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Course Overview

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Course Goals This course will prepare you to: • • • • •

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The information in this course pertains to the following SAP Software Components and releases: ECC 6.0

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SAP Software Component Information

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Maintain material masters and bills of materials Maintain routings and work centers Assign material components to operations Managed updates to various master data objects Execute reports on various master data objects Model various manufacturing options in the bill of material and routing Maintain master data using the engineering work bench

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After completing this course, you will be able to:

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Explain the organizational structures and basic data in Manufacturing and Planning Describe the manufacturing functions that support materials and bills of materials Describe the manufacturing functions that support work centers and routings Participate in configuration decisions that ensure that SAP R/3 supports company requirements Describe some of the advanced modeling features in manufacturing and planning using Bills of Materials and Task lists. Describe the features of the Engineering Work Bench

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Unit 1 Overview of Master Data for Product Management and Manufacturing

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After completing this unit, you will be able to:

Unit Contents

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Lesson: Types of Data in SAP ERP .............................................2 Procedure: Configuring SAP ERP ..........................................4 Lesson: Use of Organizational Data and Master Data in Production .......7

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Describe the types of data used in modeling and executing manufacturing in SAP ERP Identify the production planning organizational units (configuration) Identify the procurement organizational units Identify the Sales and Distribution organizational units Identify the production planning master data objects

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Unit Objectives

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This unit introduces you to how master data will be used in supporting the SAP ERP production planning and execution process. The different master data and organizational data are discused at a summary level. Each object will be covered in more detail in following lessons.

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Unit Overview

Unit 1: Overview of Master Data for Product Management and Manufacturing

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Lesson: Types of Data in SAP ERP Lesson Overview In this lesson we will discuss the different types of data that users and project team members will deal with during an implementation and after go live.

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

Describe the types of data used in modeling and executing manufacturing in SAP ERP

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Configuration Data Configuration data is often referred to as one-time data. This means that the data should not change, but if it does it will be tracked or controlled.

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Configuration data Master data Transactional data

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When dealing with a software system as robust as SAP ERP, you need to have perspective on how your business will be modeled in a software environment. In SAP ERP, users will have essentially three types of data:

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Data Types in SAP ERP

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Your company, Precision Pumps, has just purchased SAP ERP to efficiently run your business. As a member of the project team in a company that manufactures pumps, you are responsible for the introduction of basic data for manufacturing. The defined basic data will be used in the procurement, scheduling, manufacturing, and costing of all components and products necessary for the manufacturing of pumps. You must introduce the basic concepts of configuration in SAP ERP, as well as master data and organization data.

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Lesson: Types of Data in SAP ERP

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Once the configuration changes are moved to the QA server, integration testing will take place within the PP module and within the other applications in SAP ERP, such as materials management (MM) and Sales and Distribution (SD), for example. Once fully tested in the QA system, the configuration will be transferred to PROD, or the production server/client.

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During the project, team members will try different iterations of configuration in the sandbox client and test the results. If the results meet the organizations requirements, they are configured again in the golden client. From there, the Basis team moves it to the QA server for further evaluation. The Basis team will us a tool called the Change and Transport System (CTS). This allows them to track the configuration changes from DEV to QA, and QA to PROD.

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During an implementation, the SAP ERP landscape will typically consist of three servers: DEV (development), QA (quality assurance), and PROD (production). Each server may have several clients. The DEV server is where a sandbox client will exist, as well as the golden client, where the final configuration resides.

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Figure 1: Configuration in SAP ERP

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Configuring SAP ERP 1.

Enter transaction code SPRO.

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Select Reference IMG.

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Choose Production → Basic Data → Bill of Material → Control Data for Bill of Material → Define Default Parameters.

Master Data in SAP ERP Configuration will be the foundation upon which most master data will be built. Master data is often referred to as “slowly changing” data. This means the data of a particular object does not change all the time, but often several times a year.

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Figure 2: Master Data

Master data in SAP ERP is a centralized function. This means that the data is be intended to be stored once and replication is to be avoided. The master data that will be used for production planning in SAP ERP is as follows: • • • • •

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Material masters Bills of material Work centers Task lists/routings Cost centers

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PLM114

Lesson: Types of Data in SAP ERP

Business users will be limited to creating, changing, or displaying data based on their role within the organization. During implementations, each business must determine how the Product Lifecycle Management (PLM) process within SAP ERP will integrate with their specific business processes. As organizations change, so must the master data to support the business; this needs to be modeled properly within the SAP ERP environment.

Transactional Data Every day, businesses perform tens of thousands of transactions that make the business function. Some transactions are directly related to outside events with customers or suppliers. Other events are internal to the business and affect the interaction between departments within a business or division.

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Figure 3: Transactional Data

Within SAP ERP, all transactional data is related to some form of master data or configuration data. In the world of production planning, you will be executing planning runs that will be generating replenishment suggestions, generating production execution directions, or executing production confirmations. In SAP ERP production planning, all transactional data typically revolves around the material master, bill of material, or routing. In this class you will learn how master data works; however you may be asked to analyze how it works in conjunction with day-to-day business events or transactions, such as a production order.

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Lesson Summary You should now be able to: • Describe the types of data used in modeling and executing manufacturing in SAP ERP

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Lesson: Use of Organizational Data and Master Data in Production

Lesson: Use of Organizational Data and Master Data in Production Lesson Overview In this lesson you will be exposed to organizational data and its potential impact on production planning in SAP ERP.

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

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Identify the production planning organizational units (configuration) Identify the procurement organizational units Identify the Sales and Distribution organizational units Identify the production planning master data objects

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Business Example

Organizational Objects in Production Planning

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The foundation of the SAP ERP system is the organizational structure that will be configured at the early stages of your company's implementation of the software. All other configuration or master data will be built on top of the organizational structures.

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As a member of the project team, you must understand how organizational structures, production planning, and master data are used to develop an organizational plan to support existing and future business.

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To better understand the structure, you must familiarize your self with several definitions:

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Client The client is a unit within an SAP ERP system that is self-contained both in legal and organizational terms, and in terms of data, with separate master records and an independent set of tables. From a business viewpoint, the client represents a corporate group, for example. The client is the highest hierarchical level in the SAP ERP system. Specifications or data that you make and enter at this level apply to all company codes and all other organizational units. Therefor, you do not have to enter the specifications and data in the system at client level more than once. This ensures a uniform data status. Access authorization is assigned on a client-specific basis. A user master record must be created for every user in the client in which he or she wishes to work. If the Client field has not been prepopulated, each user must specify a client key when logging on to an SAP ERP client. The client key is uniquely defined in the system and is a three-digit number. In this way, the user specifies the client in which he or she wishes to work. All user input is stored and separated by client. The processing and evaluation of data is likewise carried out on a client-specific basis.

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Figure 4: Organizational Structure

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Lesson: Use of Organizational Data and Master Data in Production

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Company code A company code is the smallest organizational unit of external accounting for which a complete, self-contained bookkeeping system can be replicated. This includes the entry of all events that require posting to the accounts and the creation of a complete audit trail for balance sheets and profit-and-loss statements. A company code represents an independent unit producing its own balance sheet, for example, a company within a corporate group (client). You can set up several company codes in one client in order to keep separate sets of financial books. You can use a special Customizing function to copy a company code. In the process, company-code-dependent specifications are adopted for your new company code. A company code is defined in the system by means of a four-character alphanumeric key that is unique in the client.

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1000 is assigned to

company code

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Company code

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controlling area

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Plant

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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. To use product costing and order costing, inventory must be valuated at plant level.

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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.

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

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Storage Location The storage location is an organizational unit that facilitates the differentiation of stocks of materials within a plant. Inventory management on a quantity basis is carried out in the plant at storage-location level. The physical inventory is also carried out at this level. A storage location is defined by means of a four-character alphanumeric key that is unique in the plant.

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Plant The plant is an organizational unit within logistics that subdivides an enterprise from the viewpoints of production, procurement, and materials planning.

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Purchasing Organization Outside of production planning, other areas of the SAP ERP system need additional configuration to support their specific functional needs. In addition to the client and company code requirements, purchasing requires an additional organizational structure.

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Purchasing groups are not defined in Customizing for the enterprise structure, but in Customizing by choosing Materials Management → Purchasing → Create Purchasing Groups. The purchasing organization is an organizational unit within logistics that subdivides the enterprise according to the purchasing requirements. A purchasing organization procures materials or services, negotiates conditions of purchase with vendors, and assumes responsibility for these transactions.

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Note: The purchasing group is not assigned to other units of the enterprise structure in SAP ERP.

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A purchasing group is a key for a buyer or a group of buyers who are responsible for certain purchasing activities. Internally, the purchasing group is responsible for the procurement of a material or class of materials. Externally, it is the principal channel for an enterprise's dealings with its vendors.

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Figure 5: Purchase Organization

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Lesson: Use of Organizational Data and Master Data in Production

You can incorporate purchasing into the company structure by assigning the purchasing organization to a company code and to plants. This means that you can take into account whether purchasing is organized on a centralized or decentralized basis in your company. You can have a combination of these two organizational forms. You can assign several purchasing organizations to one company code. However, a certain purchasing organization can only belong to one company code. You can decide not to assign the purchasing organization to a company code (cross-company-code purchasing). There is an m:n relationship between purchasing organizations and plants. In other words, you can assign several plants to one purchasing organization, and one plant to several purchasing organizations.

Similar to the purchasing side of an organization, the group responsible for sales has additional unique business requirements.

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Sales Organization

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Figure 6: Sales Organization

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A sales organization is uniquely assigned to a company code, however a company code may have more than one sales organization assigned to it. If the Sales and Distribution module is used, at least one sales organization must be defined. The sales organization is the highest summation level in sales statistics. Customer master data will be created for each sales organization. Documents created throughout the Sales and Distribution process (order, delivery, and billing document) will belong to a sales organization.

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The sales organization is responsible for selling and distributing goods and services. It is liable for the products sold and responsible for a customer's rights of recourse. The sales organization can be used to represent a regional, national, or international subdivision of a marketplace in which products are sold.

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A distribution channel is a means through which saleable materials or services reach the customer. A distribution channel is assigned to a sales organization. A sales organization may have more than one distribution channel assigned to it. If the Sales and Distribution module is used, at least one distribution channel must be defined and assigned to a sales organization. A distribution channel allows customers to be treated differently depending on the channel they are assigned to. For example, a customer assigned to a wholesale distribution channel may receive preferred pricing compared to a retail distribution channel customer. A sales organization can have several divisions assigned to it, but must have at least one division. A division is used to group materials and services. A division can represent a product group or product line, which allows:

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Restricted price agreements to a certain division Statistical analysis by division

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Once your company has established an organization structure, the different business areas can proceed with developing the application-specific master data to activate the necessary functionality required to run the day-to-day activities of your business.

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Master Data Objects in Production Planning

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Shipping points are assigned to plants. A shipping point should have physical proximity to the plant to which it is assigned. More than one shipping point can be assigned to a plant. Several plants can also have a shared shipping point assigned to them, for example, several plants in same physical proximity sharing the same railroad depot.

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A shipping point can be a physical location, for example, a loading dock, a mail room, or a railroad depot. It can also be a logical location, for example, a group of employees responsible for processing next-day deliveries or less-than-truckload orders.

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The shipping point is the organizational element that manages your shipping activities. Each outbound delivery is processed at a shipping point.

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A sales area is a unique and allowable combination of a sales organization, distribution channel, and division. Each Sales and Distribution document is assigned to exactly one sales area. This assignment cannot be changed. A sales area can belong to only one company code. This relationship is created by the assignment of the sales organization to the company code in Customizing.

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Lesson: Use of Organizational Data and Master Data in Production

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Material master Bill of material Work center Routing/task list

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Within the PP application, several pieces of master data are required to carry out planning and execution functionality. The following master data objects are required to initiate planning and execution functions in SAP ERP:

Material Masters Material Master Record: Definition

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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.

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Figure 7: Master Data for Production Planning

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Unit 1: Overview of Master Data for Product Management and Manufacturing

Figure 8: Material Masters in SAP ERP

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A bill of material (BOM) is a complete, formally structured list of the components that make up a product or assembly. The list contains a description and object number for each component, together with the quantity and unit of measure. Bills of material can exist at the plant and/or client level. The header and components all contain validity dates that can be affected using Engineering Change Management.

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Bills of Material

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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 or article), a semi-finished product (subassembly), or a raw material (purchased part).

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Lesson: Use of Organizational Data and Master Data in Production

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Bills of material will be integrated with the material master and can be used in conjunction with routing to schedule a more precise usage point. These BOMs are used in material requirements planning, production, procurement, and product costing.

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A work center is a location that defines when and where production resources are required according to order requirements. In different companies, work centers are also called machine, labor, or capacity centers.

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Work Centers

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BOMs are single level. A BOM item can also contain components, so that multi-level production can be described by the single-level BOMs from the finished product, assemblies, or assemblies of the assemblies (and so on). In addition to stock items, which flow into the finished product, a BOM can also contain documents or text items.

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A BOM consists of header material and BOM items (components). The base quantity in the header material specifies the finished production quantity on which the component quantities are based. BOM items indicate individual parts and assemblies, which are identified by their material numbers.

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Figure 9: Bills of Material In SAP ERP

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Where the work is to be done How long the work should take What materials are needed for each operation What tools and fixtures are required

© 2006 SAP AG. All rights reserved.

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• • • •

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A routing defines operations and the sequence in which they are carried out. The following is also defined in the routing:

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Task Lists and Routings

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Work centers can be defined as individual or multiple machines, people, tools, and so on. Work centers are used in routings (routings, standard networks, inspection plans, maintenance task lists, and rough-cut planning profiles) and in orders.

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Figure 10: Work Centers in SAP ERP

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Lesson: Use of Organizational Data and Master Data in Production

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A routing shows operations in a sequence and acts as a template for production orders. Each step defines the work center in which specific work will be accomplished. The planned time for each operation is stored in the routing as a standard value.

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Lead time scheduling Product costing Capacity planning

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• • •

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These standard values are the basis for:

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Figure 11: Routings in SAP ERP

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Unit 1: Overview of Master Data for Product Management and Manufacturing

PLM114

Lesson Summary You should now be able to: • Identify the production planning organizational units (configuration) • Identify the procurement organizational units • Identify the Sales and Distribution organizational units • Identify the production planning master data objects

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2006/Q2

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Unit Summary

Unit Summary You should now be able to: • Describe the types of data used in modeling and executing manufacturing in SAP ERP • Identify the production planning organizational units (configuration) • Identify the procurement organizational units • Identify the Sales and Distribution organizational units • Identify the production planning master data objects

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Unit 1: Overview of Master Data for Product Management and Manufacturing

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© 2006 SAP AG. All rights reserved.

Unit 2 Organizational Data in Supply Chain Management Unit Overview

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• • •

Describe the purpose of a plant in SAP ERP Describe the purpose of a storage location in SAP ERP Describe the purpose of an MRP area in SAP ERP

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Unit Contents

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Lesson: Plants ................................................................... 22 Procedure: Configuring a Plant............................................ 25 Lesson: Storage Locations ..................................................... 27 Procedure: Configuring a Storage Location ............................. 30 Lesson: MRP Areas ............................................................. 32 Procedure: Using MRP Areas ............................................. 35

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After completing this unit, you will be able to:

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Unit Objectives

F o r

In this unit, you will be introduced to how your company's organization structure will be mapped out in SAP ERP. In addition, you will see how this organizational structure will affect your master data structures and maintenance process. Lastly, you will be introduced to the concept of configuration in the SAP ERP Implementation Guide (IMG).

Unit 2: Organizational Data in Supply Chain Management

PLM114

Lesson: Plants Lesson Overview In this lesson you will learn about plants in relation to the organizational structure and how they are integrated into master data.

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

Describe the purpose of a plant in SAP ERP

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Plants in SAP ERP

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The plant is a logistics-based organizational element that is used by all the logistics modules. The plant is assigned to a company code, and a company code may have many plants assigned to it. In production planning, the main organizational element is the plant. A plant is typically configured in conjunction with the company code and valuation area due to tax rules and regulations

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Your company currently has many locations where they store and manufacture products. In order to make the most of out of your implementation, you must be aware of how to model various installations in SAP ERP. You want to learn more about how the SAP ERP plant will fit your supply chain model.

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Business Example

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Figure 12: Definition of a Plant

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PLM114

Lesson: Plants

A plant may be defined for different purposes, depending on the role the plant will have in the organization. In Sales and Distribution, a plant can represent the location from which finished goods materials are stored and distributed. A plant may also be the location from which services are rendered. In materials management, a plant represents a location where material flow is managed. Stock requirements are managed from inbound and outbound perspectives. Material stock is consumed, planned and purchased in the plant. In production, a plant represents a manufacturing facility where materials are produced.

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Company code Business area Sales organization Purchasing organization

Plants are often determined as single geographical locations where those necessary business functions must be tracked. In certain situations, companies can combine several locations that are closely geographically located into one plant to minimize the organizational hierarchy. Due to tax reasons, some companies

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• • • •

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Once a plant is configured, it must be assigned to several other organizational elements to assure cross-functional integrations. Here is an example of where the plant will be assigned:

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When creating a new plant, you can use the plant copy function. In the process, all entries in the plant table and all Customizing and system tables that depend on it (and in which the plant occurs as the key) are taken into account. A plant is defined in the system by means of a four-character alphanumeric key that is unique in the client.

F o r

Figure 13: Plant in the Organizational Structure

Unit 2: Organizational Data in Supply Chain Management

PLM114

will split a single location into multiple plants. For example, companies will sell their finished goods to another company immediately after production, while the distribution location belongs to another facility. Both plants may exist in the same geographical location, but remain as two separate plants reporting to two separate company codes. As mentioned earlier, the plant is the key focal point for production planning. All master data, planning, and execution activities are defined and performed the plant level. Some examples of these dependencies are:

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Calendar Material master Bill of material Work center Routing Planned/production order types MRP configuration

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• • • • • • •

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© 2006 SAP AG. All rights reserved.

2006/Q2

PLM114

Lesson: Plants

1.

Choose Enterprise Structure → Definition → Logistics-General → Define, copy, delete, check plant.

2.

Choose Define Plant. Select Plant 1000 and choose

3.

Select Back twice to the dialog box and select Copy, delete, check plant.

4.

Choose

5.

Enter 1000 in Copy From field and P114 in Copy To field and choose Continue (Enter).

6.

Once completed, exit to the main menu.

7.

Choose Enterprise Structure → Assignment → Logistics-General → Assign plant to company code.

Details.

Copy Org. Object.

Review Company code 1000.

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b y

8.

Choose Enterprise Structure → Assignment → Logistics-General → Assign plant to company code.

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Review Company code 1000.

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Note: Plant P114 has been assigned to company code 1000.

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Configuring a Plant

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Note: Plant P114 has been assigned to company code 1000.

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Unit 2: Organizational Data in Supply Chain Management

PLM114

Lesson Summary You should now be able to: • Describe the purpose of a plant in SAP ERP

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2006/Q2

PLM114

Lesson: Storage Locations

Lesson: Storage Locations Lesson Overview In this lesson you will learn how the storage location is incorporated into the organizational structure and how it impacts master data in production planning.

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

Describe the purpose of a storage location in SAP ERP

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Storage Locations in SAP ERP

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The storage location is an organizational unit that facilitates the differentiation of stocks of materials within a plant. Inventory management on a quantity basis is carried out in the plant at storage-location level. The physical inventory is also carried out at this level within materials management and Inventory Management.

i n t e r n a l

Your company currently has many areas where they store products within a facility. In order to make the most of out of your implementation, you must be aware of how to model areas in SAP ERP. You want to know how the SAP ERP storage location will fit your supply chain model for planning and execution purposes.

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Business Example

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Figure 14: Storage Locations in SAP ERP

As with all organizational elements, storage locations are configuration and are defined in the IMG. A storage location is defined by means of a four-character alphanumeric key that is unique in the plant.

2006/Q2

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27

Unit 2: Organizational Data in Supply Chain Management

PLM114

The enterprise structure is created through the assignment of organizational levels to each other. A client may therefore contain several company codes. In turn, a company code may contain several plants. However, a plant can only ever belong to one single company code in the SAP system. Hint: Since the plant key is unique in a client, and a plant can only belong to one company code, by specifying the plant you simultaneously specify the company code.

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F o r

Several storage locations may be assigned to a plant, but when a certain storage location is assigned to a plant it forms a compound key. Storage locations are defined especially for a plant and are thus assigned to this plant. The storage location key need only be unique within a plant. Within a client, the same key can be used for different storage locations, since when you specify a storage location you always have to specify the plant as well.

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Figure 15: Storage Location Address

Note: To create storage locations, in the IMG, choose Enterprise Structure → Definition → Materials Management → Maintain Storage Location. Here you can create a storage location in reference to a plant.

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2006/Q2

PLM114

Lesson: Storage Locations

Upon creating a storage location, you will define a unique four-character value. This value is alphanumeric, so a company could create an exhaustive number of storage locations for each facility. In addition, when creating a storage location, companies have the opportunity to define a different address for each storage location. This may be done for one of several reasons: • •

The storage location represents a sub-contractor location where inventory is held. The storage location represents a company facility with a different shipping address.

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Once a material exists in a storage location users, will see a Storage location view on the material master. In addition, they will be able to make settings for material requirements planning (MRP) at the storage-location level in the MRP 4 view.

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To manually create storage locations, enter the storage locations for a material master record collectively. This is much less time-consuming than entering the data for each storage location individually. This can be performed from the application menu path by choosing Logistics → Production → Master Data → Material Master → Other → Enter Storage Locations (MMSC).

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Note: The standard system is set in such a way that the storage location data is created automatically for all types of receipts (goods receipt with or without reference, stock transfers, initial entry of stock balances, reversal of goods issues, and so on).

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In this step, you specify whether the automatic creation of storage location data is allowed for goods receipts. This is advisable if you want to post a goods receipt without having to maintain the storage location view of the material master record in advance. First, you have to allow automatic creation per plant. You then have to explicitly allow the creation of storage location data for each movement type. The storage location data is only created if the quantity is posted to “standard” storage location stock. It is not created for receipts into a special stock (for example, into sales order stock).

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The material master record is automatically extended the first time a goods receipt is posted for the material. All data specific to the storage location is updated in the material master record. The system can be configured in this way in Customizing by choosing Materials Management → Inventory Management and Physical Inventory → Goods Receipt → Create Storage Location Automatically.

F o r

A material can be stored at several storage locations. To store data specific to each storage location, you must create the relevant material master record (or extend an existing material master record) for each storage location. If the material master record already exists, it can be extended to include storage-location-specific data either manually or automatically.

Unit 2: Organizational Data in Supply Chain Management

PLM114

1.

In the IMG, choose Enterprise Structure → Definition → Materials Management → Maintain Storage Location.

2.

Choose

3.

Enter Plant P114 and choose

4.

Choose New Entries.

5.

Enter the storage location number OS01 and a description of OFF Site 1.

6.

Select the new storage location and select the folder Addresses of Storage locations twice.

7.

Choose new entries, place a 1 in theNO (sequential address number) field, and put any address in the fields.

8.

Choose

Execute. Continue.

Save.

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Configuring a Storage Location

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2006/Q2

PLM114

Lesson: Storage Locations

Lesson Summary You should now be able to: • Describe the purpose of a storage location in SAP ERP

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Unit 2: Organizational Data in Supply Chain Management

PLM114

Lesson: MRP Areas Lesson Overview In this lesson we will discuss the concept of MRP areas and how they may be an alternative to creating additional plants in your organizational model.

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

Describe the purpose of an MRP area in SAP ERP

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During the blueprint process of an implementation, when teams are considering the organizational structure, the will have to consider not only financial impacts but those of the logistics planning and execution.

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MRP Areas in SAP ERP

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Your company currently has many areas where they store products within a facility. To make the most of out of your implementation, you must be aware of how to model areas in SAP ERP. Often times your company has requirements to keep inventory and demand separate from other areas of the business. You want to know how the SAP ERP MRP area will fit your supply chain model for planning and execution purposes.

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Business Example

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Figure 16: Organizational Structure Overview

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Lesson: MRP Areas

In many situations, the logistics side of the business has specific requirements from customers to keep inventory and demand separate from other streams of demand. This may be due to subcontracting requirements or storing spare/service parts separate from the rest of the facility. One option companies have is creating a separate plant, but from a configuration standpoint this requires a lot of overhead and possible maintenance while having no positive financial impact. MRP areas are not part of the physical organization structure, but can use the storage locations within a plant to break up requirements and inventory during planning.

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Figure 17: MRP Areas

Note: To find MRP Areas in the IMG, choose Production → Materials Requirements Planning → Master Data → MRP Areas → Define MRP Areas.

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MRP areas are defined as part of MRP configuration. There are three types of MRP areas: plant, storage location, and Vendor (subcontractor). We will only focus on the storage location aspect since that can affect the modeling of your organizational structure.

Unit 2: Organizational Data in Supply Chain Management

PLM114

When creating MRP areas, you must specify the MRP area type, plant, and receiving storage location for Type 2 (storage location). Companies have the options of assigning one or more storage locations to each MRP area. Once an MRP area is defined, users must assign material masters to the MRP areas they wish to segregate from the rest of the plant. Note: When demand is placed at the storage location level – either through sales order, demand management, or via some dependent demand – if the material master is assigned to an MRP area that contains the storage location, all demand and inventory are kept separate from the plant.

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2006/Q2

PLM114

Lesson: MRP Areas

C S C

In the IMG, choose Production → Materials Requirements Planning → Master Data → MRP Areas → Define MRP Areas.

2.

Choose New Entries and enter the data from the table below. Field

Value

MRP Area

OS01-P114

Description

Out Sided Storage

MRP Area Type

02 - Storage Location

Plant

P114

3.

Press ENTER.

4.

Enter receiving storage location OS01and choose

5.

From the application menu, choose Logistics → Production → Master Data → Material Master → Material → Change → immediately.

6.

Enter T-F1## and select MRP 1 at Plant 1000.

7.

At the bottom of the MRP 1 screen, select MRP Areas.

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Save.

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Using MRP Areas

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35

Unit 2: Organizational Data in Supply Chain Management

PLM114

Lesson Summary You should now be able to: • Describe the purpose of an MRP area in SAP ERP

Related Information For more information as it pertains to production planning, see online help or SAP course SCM240.

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2006/Q2

PLM114

Unit Summary

Unit Summary You should now be able to: • Describe the purpose of a plant in SAP ERP • Describe the purpose of a storage location in SAP ERP • Describe the purpose of an MRP area in SAP ERP

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Unit 2: Organizational Data in Supply Chain Management

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© 2006 SAP AG. All rights reserved.

Unit 3 Material Masters Unit Overview

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After completing this unit, you will be able to:

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• • •

Unit Contents Lesson: Overview of the Material Master..................................... 41

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Describe the organizational layout of the material master List the prerequisites to creating material masters Use various methods to create material masters Describe the request process with interactive forms and explain how it might benefit your business Describe how the material master can use classification to include company-specific fields Describe how classification can be used for batch management of inventory Describe how classification can be used for variant configuration Describe different ways to update or change the material master Demonstrate the mass maintenance features of the material master Describe how the material master can be updated using the request processes with interactive forms for materials management Describe the archiving and deletion process for the material master Describe the process of influencing the field characteristics of the material master Describe Process of configuring the screen layout of the material master Set up a customized material master in Customizing Test the settings by creating a material master

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• • • •

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Unit Objectives

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In this unit you will be introduced to the concept of the SAP ERP material master. You will be instructed on the creation, maintenance, and configuration of the material master. In addition, you will execute various transactions to manage the process surrounding its life cycle.

Unit 3: Material Masters

PLM114

Procedure: Organizational Levels of the Material Master.............. 45 Lesson: Creating a Material Master ........................................... 47 Exercise 1: Creating Material Masters.................................... 61 Lesson: Classification of the Material Master ................................ 72 Exercise 2: Material Classification ........................................ 81 Lesson: Managing the Material Master ....................................... 87 Exercise 3: Managing Material Masters .................................. 95 Lesson: Configuration of the Material Master ...............................104 Procedure: Setting Up Screen Sequences ............................. 115 Exercise 4: Material Types, Field Control and Material Status ....... 119

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2006/Q2

PLM114

Lesson: Overview of the Material Master

Lesson: Overview of the Material Master Lesson Overview In this lesson you will learn about the material master at a high level and its purpose in SAP ERP.

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

Describe the organizational layout of the material master

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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.

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Introduction to the Material Master

F o r

As the project lead for implementing material master files, you must be aware of the structural design of the objects in SAP ERP. You want to learn how the material master is structured to integrate it with several business areas in your company.

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Business Example

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Figure 18: The Material Master

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Unit 3: Material Masters

PLM114

For a company, the material master record represents the central source for data on materials, and is used by various SAP logistics applications. The material can be a finished product (product or article), a semi-finished product (subassembly), or a raw material (purchased part). The material master can be valid for many different areas within the business. All data is maintained in several centralized tables, based on relevance to the particular part of the organizational structure. The material master is used by all SAP R/3 logistics applications. It controls whether a material is purchased, produced, or sold.

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•

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The basic data view includes general data, such as the material number, material description, base unit of measure, and technical data. The classification view contains user-defined class assignments for a material. The materials planning view contains plant-specific data used in procurement planning. The scheduling view contains plant-specific data used for scheduling materials for production.

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The data that you maintain in the following views is used by production planning (PP) functions:

F o r

Every area of responsibility can have a material master view. 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 to which it belongs. Each department then has its own material master record view and is responsible for the data being correct.

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2006/Q2

PLM114

Lesson: Overview of the Material Master

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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. This data is contained in the table MARA.

b y

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. This data is contained in the table MARC.

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F o r

u s e

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, reflecting a company's structure. In SAP ERP, the only elements that directly impact production planning are client, plant, and storage location.

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F o r

Figure 19: Organizational Levels of the Material Master

All data that applies to a specific storage location is stored on storage location level. This is mainly storage location stock. This data is contained in the table MARD.

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Unit 3: Material Masters

PLM114

The material master is a linkage of several tables, defined by their relationship to the organizational structure. Several of the main material master tables are: • • • • • • • •

MARA - Client MARC - Plant MARD - Storage Location EINA/EINE - Purch. Info Record Data MAKT - Material Descriptions MVKE - Sales Data MLGN - Warehouse Mgmt MBEW - Material Valuation

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2006/Q2

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Lesson: Overview of the Material Master

Organizational Levels of the Material Master 1.

Enter P-100, and select only the Basic Data 1 view.

2.

Select the MRP 1 screen and enter plant 1000.

3.

Select the Plant data/stor. 1 tab and enter 0002.

4.

Select the Sales: Sales org .1 tab, enter sales organization 1000, press ENTER, and then select the drop-down for the distribution channel value. Select 10.

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Unit 3: Material Masters

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Lesson Summary You should now be able to: • Describe the organizational layout of the material master

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Lesson: Creating a Material Master

Lesson: Creating a Material Master Lesson Overview In this lesson you will learn about the prerequisites for creating a material master, as well as the various methods of creating a material master.

Lesson Objectives After completing this lesson, you will be able to: List the prerequisites to creating material masters Use various methods to create material masters Describe the request process with interactive forms and explain how it might benefit your business

Prerequisites for Creating Material Masters

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The person who creates the first view of each material master record must define:

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The material number The industry sector The material type The unit of measure The description

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Prior to creating a material master, several pieces of information must be known in order to properly create a material master record in SAP ERP.

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As an engineer at Precision Pumps, you are responsible for the creation of material masters in SAP ERP. In doing so, you must learn the various methods of creating a material master. This will include creating a material from scratch, creating a material from an existing material master, and creating a material using profiles and other shortcuts.

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Business Example

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When you create a material master record, you must define material type for the material. The material type determines which business processes (such as sales, production, or purchasing) and functions (use of material in BOM or routing) are allowed for a material. The selection of the material type should not be taken lightly, as a wrong choice can have serious impacts.

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The material type is a configurable item and is usually controlled by costing or Inventory Management due to the large impact is has on those areas of an implementation.

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Figure 20: Material Types in SAP ERP

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Lesson: Creating a Material Master

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Figure 21: Material Type Configuration

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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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• • • • • • •

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When you create a material master record, the material type determines:

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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, semi-finished products, and finished products.

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Figure 22: Industry Sector

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Note: From within any of the Create, Change, or Display transactions, users can access the Defaults → Industry Sector menu. This transaction is user-specific, and can control the default industry sector as well as hide the industry sector once a default is set.

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The industry sector determines which data fields and screens are available for input during material master maintenance. Industry sector is one of several influencing factors. In the configuration of the material master, industry sector can act as one key in specifying whether a field is required, changeable, display only, or hidden. In addition, industry sector is used in configuration to determine what views and what sequence a user can display the material master.

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Figure 23: Material Numbering

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

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Lesson: Creating a Material Master

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. Note: Material numbering is defined at the client level. You can assign an interval to only one group. You can also change the current number of an interval manually.

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The data you enter for material number conversion determines the way material numbers are displayed in dialog functions and printouts only. This means that the information is stored in the database unconverted. Caution: The display format for the material number is effective for all clients.

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During configuration, your company can decide how to view material masters. The material master field has a maximum of 18 characters. You can configuration a template to provide breaks in the material number, for example, 123-456-789. In addition, if you do not intend to use all 18 characters from the beginning, you can specify whether leading zeros are to be displayed.

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Figure 24: Storing and Displaying the Material Number

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For every material master, a base unit of measure must be assigned. This is referred to as the stock keeping unit or the smallest unit of measure a material has consumed. This field is used client-wide and will impact all plants of any company code that uses this material master.

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In addition to the base unit of measure that the system uses for stock keeping and to execute all its calculations, other departments can use their own units of measure.

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Figure 25: Units of Measure

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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: •

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SAP ERP comes supplied with the ISO (International Organization for Standardization) unit of measure tables. Simple put, SAP ERP already has the conversions from kilograms to pounds. Conversion of other non-dimensional units of measure must be defined. This would include the conversion from pieces to pallets, for example. This is often material-specific and would have to be maintained in the material master tables.

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

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Base unit of measure (Basic Data 1): Stock keeping unit. All other units of measure you use are converted to the base unit of measure. If there is no standard formula to convert 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 (Purchasing): Unit of measure used for ordering the material. This is the default unit for purchasing functions. Sales unit (Sales: sales org 1): 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. Production unit (Work Scheduling): Unit of measure to be used in the receipt of production. When you create a production order for a material, and a production unit has been entered in both the material master record and in the routing, the system checks whether the quantity entered in the production order falls within the lot size range in the routing. Unit of issue (Work Scheduling/Whse Mgmt 1): Unit of measure for issuing the material from stock. Use this unit for goods issue and stock movement transactions. You can also use this unit for the BOM item quantity.

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When a company needs to create a new material master record, they have to match the process to the SAP ERP transactions. Listed below are several options for creating new material masters

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Creating New Materials

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Caution: The base unit of measure must not be entered in the unit of measure group.

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For materials that have similar weight and dimension characteristics, you can group together several units of measure in a unit of measure group and assign the group to a material. For each unit of measure in the group, you can enter the conversion factor to the base unit of measure. You maintain unit of measure groups in Customizing for the material master (Logistics - General).

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Figure 26: Unit of Measure Groups

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Lesson: Creating a Material Master

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

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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.

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Note: As soon as a material master record is created with MRP data and a valid MRP type, this material is then automatically included in the planning file, which is extremely important for MRP. When loading the data from a legacy system, the transaction does not create planning file entries.

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Hint: The engineering workbench (EWB) 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 that are only planned.

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Figure 27: Creating Materials with Default Values

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.

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Material Master Record Defaults To access material master data efficiently, you can: • • •

Predefine the industry sector Predefine the selection of views Predefine the selection of organization levels

To enable more efficient and accurate entry of MRP/forecast data, you can predefine several MRP/forecast profiles: • •

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

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The MRP profile allows users to set default values for MRP data fields and to 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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Creating a Material Using MRP Profiles and MRP Groups

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Hint: The above comments on the engineering workbenchalso apply here. Ensure that when using MM#1 transactions, the material type of the 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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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

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In certain companies, not all views of the material master are created immediately. This may require having new views of existing material masters created. This can be accomplished with the following transactions:

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Lesson: Creating a Material Master

The forecast profile allows users to set default values for forecast data fields and to 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. In addition to the MRP profile, users creating MRP views can use and assign MRP group to the material in the material master (MRP 1 view). The MRP group is defined in configuration under the MRP section. It is used to apply field values to a large number of materials.

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As of SAP ERP ECC (2004), a new function called Interactive Forms is available for Product Lifecycle Management (PLM) . This new functionality enables you to complete the processing of products and materials considerably more efficiently, as well as to implement company-specific standards for quality throughout the course of the process.

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In most organizations, one of the major obstacles is defining and managing a process for creating master data. A huge range of forms are used on a daily basis in all types of business, especially for processing requests and approvals. Using paper forms for such processes is singularly inefficient. Delivery and submission is very time-intensive, and usually requires direct contact with an employee. Under such conditions it is difficult for the managers responsible to follow the progress of a process.

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Creating Material Masters Using Request Processes with Interactive Forms

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Caution: When using MRP groups, be aware that the field values do not appear in the material master. This is different from the MRP profile.

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For example, the employee can use the input help for entering system data, and the entries are checked for validity. The manager is notified that the request form needs approval through the Control Center of the Guided Procedures component

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You process the forms in standardized processes that are defined in the process template. The temporal and logical sequence of the processing steps is linked to the evaluation of conditions. For example, the data required for a particular step must be complete and correct before the subsequent step can be started. The employees responsible, such as the person who makes the request, experts, and managers, are automatically integrated in the separate process steps. Although the employee processes the form offline, information is available from the SAP system.

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The electronic forms contain data on the person who makes the request and the reason for it. Additional process-specific data is added by experts, for example: important product or material data in the New Product request form, or whether stock data should be considered in the change process in the Product Change request form. The data is presented clearly, tailored to the area of responsibility of the employee, and supplemented with notes explaining the process.

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Request: New Product (physical form) Request: Product Change (physical form)

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With the help of Interactive Forms, you can compile required product and material data offline, and then enter it into the SAP system when the manager provides their approval. You can process the following interactive forms:

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Figure 28: Creating Master Data with Interactive Forms

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Lesson: Creating a Material Master

in the materials management service directory. This is where the manager either approves the data for entry in the SAP system, or rejects it and initiates a notification to the person who made the request. The design of the forms, as well as the processes, have been modeled with the functions of the Guided Procedures component (Web Application Server (WAS) → Composite Application Framework (CAF) ® → Guided Procedures (CAF-GP)). The following overview includes information about where you can find the documentation for the Guided Procedures (CAF-GP) component. •

Documentation for the application, with information on software requirements:

Simulation: New Product Request (from RTK-ERP)

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View the following simulation to learn more about this lesson: File Name: 573DF48ABE268D41B6D44449F7C39E28~NewProductRqst_IAF.sim

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Installation guide: SAP Service Marketplace at http://service.sap.com/instguides: Installation and Upgrade Guides → SAP xEPM 1.0 Installation and Configuration Guide.

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SAP Library at http://help.sap.com/: SAP NetWeaver → Composite Application Framework (CAF)→ Guided Procedures (CAF-GP).

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Exercise 1: Creating Material Masters Exercise Objectives After completing this exercise, you will be able to: • Create defaults to be used with creation of material masters • Create a material master without any template data • Create a material master using Copy From functionality

Business Example

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Your recent position will only have you creating materials for a certain section of the company. Therefore, set your user's default for the organizational values Plant 1000, Sales Organization 1000 and Distribution Channel 10, and only display organizational levels on request.

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Your recent position will only have you creating materials for a certain business areas within the company. Therefore, set your user's default for the material master views for which you are responsible for creating. Set Basic Data 1, MRP 1 - 4, Work Scheduling, Accounting 1, and Costing, to always be selected and select Create views selected so if you use any materials as templates, you will not have to look at all views to create the material.

4.

Create an MRP profile for rapid and secure maintenance of MRP data from the material record.

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Your company has decided not to use the industry sector functionality. Therefore, set your user's default for the industry sector to Mechanical Engineering, and only display industry sector on request.

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In the role of an engineer, you are tasked with creating large quantities of material masters. To make the process run more efficiently, you will use default values and MRP profiles to expedite the creation of material masters. Set your organizational level, industry sector, and view defaults as instructed below. Once completed, set up an MRP profile to populate many of the required fields in the MRP 1 - 4 views.

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Task 1: User Defaults

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As the product development engineer, you are responsible for controlling the management of the material master in your company. To start this process, you need to understand the different ways that a material master can be created. You want to find out which method matches with your business process.

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Create an MRP profile, SF##, with the description Semi Finished Group ## for use in creating material masters with the material type Semi-Finished Product. Use the parameters in the following table for this exercise. Note: Solution steps will appear after the table in the Solutions section.

Maintenance Strategy

MRP Type

Fixed value

MRP controller

Default

ABC Indicator

Fixed value

In-house production time

Default

5 days

Scheduling margin key

Default

002

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Lot Size (Materials Planning)

Fixed value

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Purchasing group

Default

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Planning time fence

Default

10 days

Component scrap in %

Default

1 %

Indicator: Backflush

Fixed value

PD 0## A = important material

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Default Value

EX = exact

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Your supervisor has given you the specs on a new pump that has just come out of research and development. She has asked you to enter the material master into the system so that one of your colleagues can begin building the bill of material. No material currently has the same attributes, so you will

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As a design engineer, you will be required to create material masters every day. You will use the defaults created in the previous task to speed up the process. In this section, you will be required to create five material masters. This will include two finished products and three semi-finished products.

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Task 2: Creating Material Masters

1.

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Data of MRP profile SF##

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create the new material with no template data. Use the following data to support the creation of the new finished production: T-F## (Rotary Pump GR##) at plant 1000. Note: Solution steps will appear after table in the Solutions section. Entry Screen

Data

Material Number

T-F##

Material Type

Finished Product

Basic Data 1

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PC - piece

Base Unit of measure

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Rotary Pump GR ##

MRP Type

PD

MRP controller

0##

Lot Size

EX - Lot for Lot

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Material Description

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MRP 1

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Scheduling margin key

001

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In house Production

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MRP 3

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Strategy Group

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Valuation Class

7920 - finished product

Price Control

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Research and development has just made an significant improvement to the T-B1## pump casing. The changes are significant enough to require a new material master versus an engineering revision. Create the following material master record by copying from reference material: A Semi-Finished Product with material number T-B## (## = group number) in plant 1000, copied from material T-B1## using your default views. Change the description to GR## Casing. Continued on next page

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

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Research and development has just made another significant improvement to the 102–100 pump casing. The changes are significant enough to require a new material master versus engineering revisions. This new casing will be used in several products as a substitute part. Create the following material master record by copying from reference material: A Semi-Finished Product with material number T-Z## (## = group number) in plant 1000, copied from material 102–100 using your default views. Change the description to GR## Alt Casing. In addition, to speed up maintenance, use the MRP profile (SF##) that you created in a previous exercise step.

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Your supervisor has given you the specs on a new centrifugal pump that has just come out of research and development. She has asked you enter the basic data information of the new pump. The balance of the views will be entered at a later date. No material currently has the same attributes, so you will create the new material with no template data. Use the following data to support the creation of the new finished product: T-F77## (Centrifugal Pump GR##) at plant 1000.

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T-F77##

Material Type

Finished Product

Basic Data 1

Data

material Description

Centrifical Pump GR ##

Base Unit of measure

PC - piece

You have just been notified by purchasing that they have come to an agreement with your rubber supplier. This agreement is to sell back the scrap rubber that is made during the stamping of gaskets for your pumps. Create a Semi-Finished Product with material number T-G## (## = group number) in plant 1000, copied from material 100-120 using your default views. Change the description to GR## Scrap Rubber. In addition, this will be a co-production, so set the co-product indicator on the MRP 2 view, and you will have to change the valuation class to 7900 - Semi Finished products.

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Data

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Entry Screen

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Note: Solution steps will appear after table in the Solutions section.

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Solution 1: Creating Material Masters Task 1: User Defaults In the role of an engineer, you are tasked with creating large quantities of material masters. To make the process run more efficiently, you will use default values and MRP profiles to expedite the creation of material masters. Set your organizational level, industry sector, and view defaults as instructed below. Once completed, set up an MRP profile to populate many of the required fields in the MRP 1 - 4 views.

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Enter Mechanical Engineering as Industry Sector and Finished Goods as Material Type

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From the menu, choose Defaults → Industry Sector.

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Enter Mechanical Engineering, and select Hide Industry Sector on Initial Screen.

e)

Choose Continue

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Choose Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately (MM01).

b)

From the system menu, select Defaults →Organizational levels.

c)

Enter the following data:

d)

Org Levels

Copy To:

Copy From:

Plant

1000

1000

Sales Org

1000

1000

Distribution Channel

10

10

Select Org Level profiles only on Request, then choose Continue

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Your recent position will only have you creating materials for a certain section of the company. Therefore, set your user's default for the organizational values Plant 1000, Sales Organization 1000 and Distribution Channel 10, and only display organizational levels on request.

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Choose Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately (MM01).

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Your company has decided not to use the industry sector functionality. Therefore, set your user's default for the industry sector to Mechanical Engineering, and only display industry sector on request.

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4.

Your recent position will only have you creating materials for a certain business areas within the company. Therefore, set your user's default for the material master views for which you are responsible for creating. Set Basic Data 1, MRP 1 - 4, Work Scheduling, Accounting 1, and Costing, to always be selected and select Create views selected so if you use any materials as templates, you will not have to look at all views to create the material. a)

Choose Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately (MM01).

b)

From the system menu, choose Defaults →View.

c)

Select Basic Data 1, MRP 1 - 4, Work Scheduling, Accounting 1, and Costing and select Create views selected .

d)

Choose Continue

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Create an MRP profile for rapid and secure maintenance of MRP data from the material record.

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Note: Solution steps will appear after the table in the Solutions section.

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Maintenance Strategy

Default Value

MRP Type

Fixed value

MRP controller

Default

ABC Indicator

Fixed value

In-house production time

Default

5 days

Scheduling margin key

Default

002

Lot Size (Materials Planning)

Fixed value

Purchasing group

Default

PD 0## A = important material

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EX = exact 000

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Field Name

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Data of MRP profile SF##

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Create an MRP profile, SF##, with the description Semi Finished Group ## for use in creating material masters with the material type Semi-Finished Product. Use the parameters in the following table for this exercise.

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Field Name

Maintenance Strategy

Default Value

Planning time fence

Default

10 days

Component scrap in %

Default

1 %

Indicator: Backflush

Fixed value

2 = work center decides

a)

Choose Logistics → Production → Master Data → Material Master → Profile -> MRP Profile → Create (MMD1).

b)

First select the fields using the Selection Screen button, then select the default values using Screens 1 and 2.

c)

When complete, select Save

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As a design engineer, you will be required to create material masters every day. You will use the defaults created in the previous task to speed up the process. In this section, you will be required to create five material masters. This will include two finished products and three semi-finished products.

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Data

Material Number

T-F##

Material Type

Finished Product

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Entry Screen

Basic Data 1 Material Description

Rotary Pump GR ##

Base Unit of measure

PC - piece

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Note: Solution steps will appear after table in the Solutions section.

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Your supervisor has given you the specs on a new pump that has just come out of research and development. She has asked you to enter the material master into the system so that one of your colleagues can begin building the bill of material. No material currently has the same attributes, so you will create the new material with no template data. Use the following data to support the creation of the new finished production: T-F## (Rotary Pump GR##) at plant 1000.

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MRP 1 MRP Type

PD

MRP controller

0##

Lot Size

EX - Lot for Lot

MRP 2 In house Production

1

Scheduling margin key

001

MRP 3 10

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S-Standard Price

a)

Choose Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately (MM01).

b)

Enter the information as described in the table above. Use the ENTER key to move to the next tab.

c)

At the Costing 1 view, select Save to save your data.

or answer Yes to the question

a)

Choose Logistics → Production → Master data → Material master → Material → Create (General) → Immediately (MM01).

b)

Enter the material number T-B## and material type for Semi-Finished goods. Enter T-B1## as the copy from material.

c)

In the Basic Data 1 view, change the description to GR## Casing.

d)

Choose Save

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Research and development has just made an significant improvement to the T-B1## pump casing. The changes are significant enough to require a new material master versus an engineering revision. Create the following material master record by copying from reference material: A Semi-Finished Product with material number T-B## (## = group number) in plant 1000, copied from material T-B1## using your default views. Change the description to GR## Casing.

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Price Control

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7920 - finished product

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Valuation Class

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Accounting 1

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Lesson: Creating a Material Master

3.

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

Enter the material number T-Z## using reference material 102–100.

c)

Select Organizational levels, and enter your MRP Profile SF## Choose Continue .

d)

A warning will appear that the profile was copied from reference material. Be sure to click the New Entry button and enter your profile SF## once again before continuing.

e)

In the Basic Data 1 view, change the description to GR## ALT Casing.

f)

Before saving, review your MRP 1- 4 views to see if your profile has had any affect.

g)

Choose Save

Your supervisor has given you the specs on a new centrifugal pump that has just come out of research and development. She has asked you enter the basic data information of the new pump. The balance of the views will be entered at a later date. No material currently has the same attributes, so you will create the new material with no template data. Use the following data to support the creation of the new finished product: T-F77## (Centrifugal Pump GR##) at plant 1000. Note: Solution steps will appear after table in the Solutions section. Entry Screen

Data

Material Number

T-F77##

Material Type

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b)

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Choose Logistics → Production → Master data → Material master → Material → Create (General) → Immediately (MM01).

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a)

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Research and development has just made another significant improvement to the 102–100 pump casing. The changes are significant enough to require a new material master versus engineering revisions. This new casing will be used in several products as a substitute part. Create the following material master record by copying from reference material: A Semi-Finished Product with material number T-Z## (## = group number) in plant 1000, copied from material 102–100 using your default views. Change the description to GR## Alt Casing. In addition, to speed up maintenance, use the MRP profile (SF##) that you created in a previous exercise step.

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4.

Unit 3: Material Masters

Data

material Description

Centrifical Pump GR ##

Base Unit of measure

PC - piece

a)

Choose Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately (MM01).

b)

Enter your material number and material type and select Views. Choose , then select Basic Data 1, and choose . Deselect all

c)

After entering in the data in the Basic Data 1 view, choose Save answer Yes to the question to save your data.

or

b y

c)

Use the ENTER key to move through the views.

d)

On the MRP 2 view, set the Co-product indicator, and continue pressing the ENTER key.

e)

On the Accounting 1 view, change the valuation class to 7900 Semi Finished products.

f)

Choose Save

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Enter the material number T-G## and material type “Semi Finished ”using reference material 100-120.

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b)

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Choose Logistics → Production → Master data → Material master → Material → Create (General) → Immediately (MM01).

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a)

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You have just been notified by purchasing that they have come to an agreement with your rubber supplier. This agreement is to sell back the scrap rubber that is made during the stamping of gaskets for your pumps. Create a Semi-Finished Product with material number T-G## (## = group number) in plant 1000, copied from material 100-120 using your default views. Change the description to GR## Scrap Rubber. In addition, this will be a co-production, so set the co-product indicator on the MRP 2 view, and you will have to change the valuation class to 7900 - Semi Finished products.

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Basic Data 1

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PLM114

Lesson: Creating a Material Master

Lesson Summary You should now be able to: • List the prerequisites to creating material masters • Use various methods to create material masters • Describe the request process with interactive forms and explain how it might benefit your business

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Lesson: Classification of the Material Master Lesson Overview In this lesson, you will learn how classification can be applied to the material master in order to addition additional custom fields for detailing the material, as well as adding more information to lots of inventory.

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

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b y

As the project lead for implementing material master files, you have several requirements regarding how to add custom fields to the material master. In this lesson you will learn the basic concept of how classification can be used to support material classification, Batch/Lot management, and variant configuration (features and options).

Use of Material Classification

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During the evaluation of your product data management process, your company may realize that it needs custom fields to provide the organization with more information on master data or transactional data. Without having to modify the delivered SAP tables, companies can use the classification system to add fields to the material master for information purposes, or to provide more information about existing inventory.

i n t e r n a l

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Business Example

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• •

Describe how the material master can use classification to include company-specific fields Describe how classification can be used for batch management of inventory Describe how classification can be used for variant configuration

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Lesson: Classification of the Material Master

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Figure 29: Classification of Master Data

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Functions of the classification are:

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To find an appropriate object To find similar objects To establish that no appropriate object exists

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• • •

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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 match codes and systematically-structured number assignment.

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Setup of Classification

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• • • • •

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SAP ERP classification consists of the following components: Characteristic maintenance Class types Class maintenance Classification (assignments) Object search Note: Course PLM130 contains more information on the SAP classification system.

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001 - Material Class 023 - Batch Management 200 - Material (configurable) 300 - Material (variant configuration)

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• • • •

A class can contain one or more characteristics. Within the class, companies can further restrict the characteristic values. A class will then be attached to the material master to specify the custom fields that were needed. A characteristic value represents the specification of a particular attribute, for example, 10 cm, DIN 931, cast iron.

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A class type describes a group of objects that have common or similar specifications. When creating a class, a user must specify a class type. Class types control how the classification can be used for various objects. The following classes can be used in conjunction with the material master:

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A characteristic describes specifications of an object, such as length, width, weight, color. Essentially, they are user-defined fields, which are defined as master data. Each characteristics must have a data type (numeric, characteristic, date, and so on). Companies define the length of the field, a template, and limits or ranges to what values can be used. The same characteristic can be used many different times for different purposes.

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Classification can be used to describe or group objects together that have some likeness, but also differences. An object is a classifiable unit (such as a material, vendor, or work center).

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Figure 30: Classification Functions

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Lesson: Classification of the Material Master

Follow these steps to maintain classes: 1. 2. 3. 4.

Define characteristics and allowed characteristic values. Maintain the class, including assigning characteristics. Maintain the objects (for example, materials), including assigning them to one or more classes and assigning values to them. Search for objects.

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Figure 31: Characteristic Value Assignment

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You can use characteristic values in various ways when using classification to determine a material number. For instance you can: Link several entries in one line using OR. Link entries in several lines using AND. Use F4 help to display possible entries for selection criteria.

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• • •

Searching Using Classification The classification system makes it easy to find objects (for example, materials).

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In particular, batch management is used in Supply Chain Management. A batch can be followed through the whole supply chain, from the entry of the raw materials through the production of the finished product, and all the way to the sales and delivery to the customer.

F o r

A batch master record is identified by an alphanumeric batch number. You can select the level at which you want the batch number to be unique in accordance with the structure of your plant, company, and operational requirements.

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To assign a batch to a material at the various points in the supply chain, you create a batch master record. For example, if the subset of a material that is subject to batch management requirement leaves a production process (process order) with certain specifications, it is posted to the stock with a batch number and can then be clearly identified.

C S C

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Some industry sectors, in particular in the process industries, need to work with the homogeneous subsets of a material or a product, which means, batches along their entire supply chain. Batch management is integrated with all the applications of the SAP ERP and supports the management and processing of the batches and lots in all the business processes of a company.

b y

Use of Batch Classification

u s e

After you have set up classification, you can use it to find a material number and copy the number to your application.

i n t e r n a l

Figure 32: Finding a Material

PLM114

Lesson: Classification of the Material Master

This material number is unique at the client level. The uniqueness of the batch number can be defined at the following levels: • • •

In combination with a plant and material. In combination with a material number At the client level

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F o r

Use of Variant Configuration in the Material Master In some industries, it makes sense to allow customers to request a product with many options that suit their exact needs. However, if the number of options is large, and no two products are likely to be exactly the same, companies could end up with more master data than is feasible to manage. A personal computer (PC), for example, may have different hard drive options, processors, or graphics

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If a material is to be produced in batches and is subject to inventory management, you must set the Batch Management indicator in the material master views Purchasing, Work Scheduling, or Warehouse Management.

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Normally, the data of a material master record is valid for all the batches assigned to it. In contrast, a batch master record contains the data that uniquely identifies a batch and characterizes it as a non-reproducible unit. You can further describe batch properties by classifying them in a class of the class type, 023 Batch.

b y

In SAP ERP, batch master records depend on the corresponding material master records. Batches are created for a material. The batch object contains the key fields: Material, Batch, and Plant. The Plant field is relevant only if the plant level is used as the batch level.

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Figure 33: Materials and Batches

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and sound options. This PC, therefore, has a large number of variants. Like the PC scenario, your company may have a situation in which it manufactures or sells products of which some exist in many variations. In order to reduce your workload and storage costs, and to enable you to maintain every possible end product variant, you choose to use the SAP ERP solution for variant configuration.

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Figure 34: Configurable Personal Computer

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Products with variants often have dependencies between the individual characteristics in which, not all combinations of characteristics are allowed. In the case of the pump, for example, a rotary pump with manual and electric drive may

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You maintain object dependencies for the BOM components and task list operations that can only be selected for particular variants. Before you use variant configuration productively, you should simulate the configuration. This allows you to check whether all the data has been correctly maintained.

C S C

You must also maintain the necessary settings for the configurable material in the material master. You create a configuration profile by specifying the configuration parameters and allocating the material to the class with the characteristics that describe it. The components and operations for a material are specified in a super BOM and a super task list.

b y

Many steps are necessary to build up the master data for a configurable material. First, you must use the SAP classification system to describe the product characteristics. You allocate the characteristics to a class used for variant configuration. You then maintain object dependencies for characteristics and characteristic values so that only allowed values can be chosen. These object dependencies are rules which define which components are compatible with others.

PLM114

Lesson: Classification of the Material Master

be available, but a piston pump may only be available with an electric drive. The term configurable product is used to denote a product that can be manufactured in several variants. It comprises all the possible characteristics of the product, and is therefore not representative of any single product. In the case of products that exist in many variants, the Super BOM contains all the parts that might be required to manufacture the configurable material. The parts actually required can be determined from the object dependencies. Likewise, the Super Routing contains all the operations that could be needed to manufacture the configurable material. The operations and production tools and resources that are actually needed for manufacture can be determined from the object dependencies.

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A special product structure is dynamically generated for a configurable material during sales order processing.

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Lesson: Classification of the Material Master

Exercise 2: Material Classification Exercise Objectives After completing this exercise, you will be able to: • Add custom fields to your materials using standard SAP functions

Business Example

2.

List the characteristics that belong to class 100

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In a previous lesson you created a new pump T-F## at plant 1000. You want to classify this new pump using existing characteristics in the system. Review the details of the material class 100 - Pumps. Use class 100 and class type 001.

Characteristic

Description

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1.

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As a product engineer, your companies business been to growing steadily over the past year. You find yourself creating new part numbers every day and the user community is finding it difficult to search and find the necessary material numbers. In order to make their jobs more efficient you have decided to begin classifying your material masters. Review existing classification data to see if it will work with your new pumps

i n t e r n a l

Task 1: Review Classification Data

F o r

As a product design engineer, you are responsible for ensuring that material masters have all the necessary information for the user community to process daily business transactions. As your business begins to grow you find that you are creating new part numbers every day and the user community is finding it difficult to search and find the necessary material numbers. In order to make their jobs more efficient you have decided to begin classifying your material masters.

F o r

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3.

What values, if any, have be assigned to C001 - Pump lift? Hint: Select the characteristic and select Display Values Continued on next page

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Values

Task 2: Classifying Material Masters In a previous task, you reviewed existing classification data to support adding custom fields to the material master. Classify your new pump and see if you can find it and others like it using the Find function and classification.

o n l y

Update your material master for pumpT-F## by adding the classification view and by assigning it to material class 100 - Pumps. Give it the following data:

20 m3

u s e

Turning Speed

1000

Material

cast iron (GRAUGUSS)

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Pump Capacity

Usage

Industrial(INDUSTRIE)

b y

10 m

82

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

Value

Pump Lift

10 m

Pump Capacity

20 m3

Turning Speed

1000

© 2006 SAP AG. All rights reserved.

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Pump Lift

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Value

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Characteristics

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Note: If you have not already done so, you will have to create the classification view.

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1.

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PLM114

Lesson: Classification of the Material Master

Solution 2: Material Classification Task 1: Review Classification Data As a product engineer, your companies business been to growing steadily over the past year. You find yourself creating new part numbers every day and the user community is finding it difficult to search and find the necessary material numbers. In order to make their jobs more efficient you have decided to begin classifying your material masters. Review existing classification data to see if it will work with your new pumps

C S C

b y

u s e

b)

Enter class 100 and class type 001 and choose Display

.

List the characteristics that belong to class 100 Characteristic

Description

C001

Pump Lift

C002

Pump Capacity

C003

Turning Speed

C004

Material

C005

Usage

b y

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Use the menu path Cross Application Components → Classification System → Master Data → Classes (CL02).

u s e

3.

a)

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2.

In a previous lesson you created a new pump T-F## at plant 1000. You want to classify this new pump using existing characteristics in the system. Review the details of the material class 100 - Pumps. Use class 100 and class type 001.

What values, if any, have be assigned to C001 - Pump lift? Hint: Select the characteristic and select Display Values

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Values 10 m 20 m 30 m 40 m Your instructor may have added another characteristic during a class demonstration via the material master. Continued on next page

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Task 2: Classifying Material Masters In a previous task, you reviewed existing classification data to support adding custom fields to the material master. Classify your new pump and see if you can find it and others like it using the Find function and classification. 1.

Update your material master for pumpT-F## by adding the classification view and by assigning it to material class 100 - Pumps. Give it the following data:

C S C

b y

Pump Lift

10 m

Pump Capacity

20 m3

Turning Speed

1000

Material

cast iron (GRAUGUSS)

Usage

Industrial(INDUSTRIE)

a)

Choose Logistics → Production → Master Data → Material Master → Material → Create → Immediately (MM01).

b)

Enter material T-F## and select Views. Select Classification and choose Continue .

c)

Enter class 100 and press Enter.

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after

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

Continued on next page

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2.

Enter the data from the above table; make sure to choose selecting a value and choose Save .

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d)

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Note: If a class type other than 001 appears in your material master, choose Extras → Change class type and enter class type 001.

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Value

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Characteristics

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Note: If you have not already done so, you will have to create the classification view.

PLM114

Lesson: Classification of the Material Master

Characteristics

Value

Pump Lift

10 m

Pump Capacity

20 m3

Turning Speed

1000

a)

Choose Cross Application → Classification System → Find → Find Objects in Class.

b)

Enter class 100 and class type 001, and press Enter.

c)

Enter your pump height, pump capacity and turning speed, and choose Find in Initial Class.

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Lesson Summary You should now be able to: • Describe how the material master can use classification to include company-specific fields • Describe how classification can be used for batch management of inventory • Describe how classification can be used for variant configuration

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Lesson: Managing the Material Master

Lesson: Managing the Material Master Lesson Overview In this lesson you will learn how to manage changes to existing material masters using various functions in SAP ERP

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

•

Describe different ways to update or change the material master Demonstrate the mass maintenance features of the material master Describe how the material master can be updated using the request processes with interactive forms for materials management Describe the archiving and deletion process for the material master

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Creating new screens for existing materials Changing the material type Making simple field changes Managing changes through statuses Performing mass maintenance of several materials Maintaining materials through interactive forms Archiving and deleting materials at end of life cycle

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• • • • • • •

Extending the Material Master When material masters are created, all of the information may not have been available. This may result in some views not getting created.

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Listed below are the different maintenance features that your company may choose to use in managing the changes in the material master:

Over the course of time, attributes of the material master will change. Therefore you must be aware of the different change functions of the material master in order to better incorporate your business processes with those of SAP ERP.

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Overview of Updating the Material Master

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As the project lead for implementing material master files, you are responsible for the process to manage changes to the material master. You must begin to develop some standard business processes to work with updating and maintaining material masters.

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Business Example

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By using the transaction Extend Material View(s), you can extend the material master record by adding more views. This transaction can be found under Logistics → Production → Master Data → Material Master → Other → Extend Material View(s) (MM50). The following questions should be answered:

u s e

Which departments have to extend a material master record? Which material master records does a single department have to extend?

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F o r

Work scheduling

A

Accounting

B

Classification

C

MRP

D

Purchasing

E

Production resources/tools

F

Costing

G

Basic data

K

© 2006 SAP AG. All rights reserved.

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Maintenance status

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Department

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Important maintenance statuses are listed in the following table. Others are available.

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• •

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Figure 35: Extending the Material Master

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Lesson: Managing the Material Master

See maintenance status in transaction MM50, Extend Material View(s). Hint: If additional views are added to the existing master record, you can also use the Create material function.

Changing the Material Type After a material master is created, there may be a need for changing the material type. This may be a problem if transactions have already been posted. •

•

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The same G/L account is used. The same quantities and values are updated.

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Material Master Updates

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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

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• • • •

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Material Status Throughout the lifecycle of a product, changes will be both major and minor in nature. When major changes occur, a business will need ways of warning or preventing certain business activities from occurring. By configuration and using the material status, companies can restrict or warn other business areas of changes that will be impacting their areas.

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These transactions do not limit you to which or how many fields you can maintain at one time.

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After a material is created, business situations will require periodic updates to the material master. Based on the type of change, your business will have to match the process with the transaction:

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– –

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•

Because 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:

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The material status allows you to control where a material can be used in business applications. You define the material status in the material master record in accordance with the material, client, and plant. You can limit the use of a material in different ways:

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• •

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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,

•

Choose Extras → Status information in any screen.

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• • • • • • • •

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Purchasing PP Master Data Demand Management Production Execution Quality Management Plant Maintenance Inventory Management Costing

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The material status in created in customizing. Users can set warnings or errors in the following business areas:

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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 start this function when creating, displaying, or changing a material master record. Proceed as follows:

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Figure 36: Material Status

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Lesson: Managing the Material Master

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).

Updating Material Masters with Mass Maintenance As of Release 4.5x, a mass maintenance tool is available to update the material master. The mass maintenance feature will reach a majority of the fields in the material master

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Figure 37: Mass Maintenance of Material Master

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Mass maintenance enables many objects to be changed at the same time. Only users with the relevant experience should therefore use this tool. To perform mass maintenance, follow these steps: 1. 2. 3. 4.

Start the transaction for mass maintenance, MM17. If you have already defined a variant, 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.

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• Change only those fields that have a definite current value • Display previous value • Test changes Save the data.

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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 choose Change Field Values. You have the following options:

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Archiving the Material Master

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As a material approaches the end of its life cycle it should be removed from the data base. You can flag materials for deletion by setting the deletion flag in the material master record. 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.

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The system will perform a consistency check for the data you changed. Changes that lead to data discrepancies are not executed and a note is entered in the log.

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The system selects the data records. Depending on how many data records you have selected, the system may ask whether you would like to continue working in the dialog or whether you would like to perform the changes in the background. If you choose the second option, a workflow will inform you later that the changes you made were carried out. If you continue working in the dialog, the system will display the data records you have selected.

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Lesson: Managing the Material Master

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1. 2. 3.

Material master is flagged for deletion. Material master is selected for a reorganization run. Reorganization run is executed.

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Hint: During the reorganization run, the system checks whether material may be deleted and whether material may be archived.

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Deletion is carried out in these steps:

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All records flagged for deletion are deleted during a reorganization run provided they are no longer being used, for example, as a BOM header.

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Figure 38: Deleting a Material

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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 or reorganization. Archived material master records can be displayed, but they cannot be retrieved.

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Archiving and reorganization are handled in greater detail in the administration courses.

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Using transaction MM71, Archive/Delete, you can see which other objects need to be deleted prior to a material master. By clicking the Network Graphic icon , you can see which objects needed to be deleted prior to deleting and archiving the material master.

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Figure 39: Archiving a Material

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Lesson: Managing the Material Master

Exercise 3: Managing Material Masters Exercise Objectives After completing this exercise, you will be able to: • Update material masters using the Extend function • Update material masters interactively • Update material masters with mass processing • Delete and archive materials

Business Example

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As the business process owner for the material master life cycle, you are experimenting with the idea of creating the material master in parts. With this concept, engineering would develop the client views (Basic data/Classification) and then the functional departments would be responsible for upkeeping their own views. Extend the finished product T-F77## to plant 1000 and create the MRP 1 - 4 views (D) and Work Scheduling view (A), using the Extend Material View(s) transaction. Include the following data: Note: Maintain work scheduling first, save your entries, and then maintain the MRP views. Press Enter through any necessary messages. Continued on next page

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Your new pump T-F77## has slightly different dimensions from the other pumps you work on. This will cause the alternative units of measure to differ from the other pumps. Change the alternative units of measure so that 4 pumps go into a carton, and 8 cartons per pallet.

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As the business process owner for the material master life cycle, you are reviewing the different methods to maintain the material master. The different methods will include manual changes, extending the material master, and mass changes. Execute the following task and determine how you will incorporate the transactions into your business process.

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Task 1: Updating the Material Master

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As the process design engineer manager, you are responsible for entire material master management process. To do your job efficiently, you must better understand how the different transactions work in updating the material master in order for you to develop a business process. Therefore you will execute several updates to existing material masters in order to better understand the functionality in SAP ERP.

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Field Name

User Entry

Production Scheduler

0##

Purchasing Group

0##

MRP Type

PD

MRP Controller

0##

Lot Size

EX

In House Production

2 days

Sched. Margin Key

001

Strategy Group

40

Selection Method

2 - Selection by Production Version

Although you are considering having each department maintain their own views, you are still in charge of maintaining the entire material master. The Production manager for you pumps has just asked that you update the material master with the correct production scheduler. Using mass maintenance update all your pumps T-F*## in plant 1000, with the production scheduler 0##.

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A finished product with material number T-D## (## = group number) in plant 1000, copied from material T-F1## using your default views. Change the description to GR## Pump Obsolete. 2.

Planning has informed you that the material T-D## at plant 1000 is obsolete. Your company's procedures prevent you from immediately deleting a material master. Archiving will take place several months from now but for time being you must set the deletion flag for the material. Flag material master record T-D## for deletion.

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Your business creates new replacement parts every day. To minimize risk, your company wants to be more expeditious in obsoleting materials. To test this process, you create a material through which you can simulate the process of obsoleting the material. Create the following material master record by copying from a reference material:

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1.

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Your research and development department is creating new materials to replace existing materials every day. To make sure that a material is truly obsolete, you must update the material master to make this so. You will create a new material master to see how material/plant status and the deletion flag to obsolete a material.

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Task 2: Deleting Material Masters (if enough time)

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Unit 3: Material Masters

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Lesson: Managing the Material Master

3.

To make sure the deletion flag works, try to perform a goods issue using transaction code MB1C for your material T-D## at plant 1000, storage location 0002 using movement type 501.

4.

To prevent such issues from happening, you want to use a material status to prevent the material from being used at all. Change your material T-D## by inserting an X-plant/materials status that identifies the material as obsolete. Material/plant status OB - Obsolete Materials has been created to prevent any logistics activities from happening until the material can be archived.

5.

After applying the obsolete material status, try to receive another goods receipt to see if this will prevent possible mishaps with obsolete materials. Use transaction code MB1C for your material T-D## at plant 1000, storage location 0002 using movement type 501.

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Caution: Do not save your entries.

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Caution: Do not save your entries.

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Solution 3: Managing Material Masters Task 1: Updating the Material Master As the business process owner for the material master life cycle, you are reviewing the different methods to maintain the material master. The different methods will include manual changes, extending the material master, and mass changes. Execute the following task and determine how you will incorporate the transactions into your business process.

Enter your material, select Organization Levels and choose Basic Data 1.

c)

From the Basic Data 1 screen, choose Go to Additional Data, and select the Units of Measure view.

d)

Add the data mentioned above:

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b)

32 pc = 1 pallet

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As the business process owner for the material master life cycle, you are experimenting with the idea of creating the material master in parts. With this concept, engineering would develop the client views (Basic data/Classification) and then the functional departments would be responsible for upkeeping their own views. Extend the finished product T-F77## to plant 1000 and create the MRP 1 - 4 views (D) and Work Scheduling view (A), using the Extend Material View(s) transaction. Include the following data: Note: Maintain work scheduling first, save your entries, and then maintain the MRP views. Press Enter through any necessary messages.

Continued on next page

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2.

Save

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e)

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Note: All units of measure are converted from the base unit of measure.

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4 pc = 1 carton

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Choose Logistics → Production → Master Data → Material Master → Material → Change → Immediately (MM02)

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a)

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Your new pump T-F77## has slightly different dimensions from the other pumps you work on. This will cause the alternative units of measure to differ from the other pumps. Change the alternative units of measure so that 4 pumps go into a carton, and 8 cartons per pallet.

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1.

Lesson: Managing the Material Master

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Production Scheduler

0##

Purchasing Group

0##

MRP Type

PD

MRP Controller

0##

Lot Size

EX

In House Production

2 days

Sched. Margin Key

001

Strategy Group

40

Selection Method

2 - Selection by Production Version

a)

Choose Logistics → Production → Master Data → Material Master → Other → Extend Material View(s) (MM50).

b)

Select maintenance status D - MRP and A - Work scheduling, and enter your material T-F77##, and then choose Execute .

c)

Select the line for T-F77## and choose Maintain Materials.

d)

Press Enter through the error message and enter plant 1000.

e)

Enter the data in the above chart and choose Save

when finished.

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Although you are considering having each department maintain their own views, you are still in charge of maintaining the entire material master. The Production manager for you pumps has just asked that you

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User Entry

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Field Name

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Choose Logistics → Production → Master Data → Material Master → Material → Mass Maintenance (MM17).

b)

In the Tables tab, select the Plant Data for Material table.

c)

In the Fields tab, choose Find , enter Prod, and choose Continue . Continue searching using the search function until the Production Scheduler line appears.

d)

Select the line containing Production scheduler: MARC-FEVOR and choose Execute .

e)

Enter your material T-F*## and plant 1000, and choose Execute

f)

In the new view, enter 0## in the New Values field.

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Choose Carry out Mass Change

h)

Choose Save

.

.

, and Continue through any warnings.

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Task 2: Deleting Material Masters (if enough time)

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a)

Choose Logistics → Production → Master data → Material master → Material → Create (General) → Immediately (MM01).

b)

Enter material number T-D## and use reference material T-F1##.

c)

In the Basic Data 1 view, change the description to GR## Pump Obsolete.

d)

Choose Save

.

Continued on next page

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A finished product with material number T-D## (## = group number) in plant 1000, copied from material T-F1## using your default views. Change the description to GR## Pump Obsolete.

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Your business creates new replacement parts every day. To minimize risk, your company wants to be more expeditious in obsoleting materials. To test this process, you create a material through which you can simulate the process of obsoleting the material. Create the following material master record by copying from a reference material:

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1.

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Your research and development department is creating new materials to replace existing materials every day. To make sure that a material is truly obsolete, you must update the material master to make this so. You will create a new material master to see how material/plant status and the deletion flag to obsolete a material.

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update the material master with the correct production scheduler. Using mass maintenance update all your pumps T-F*## in plant 1000, with the production scheduler 0##.

PLM114

Lesson: Managing the Material Master

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a)

Use menu path Logistics → Production → Master Data → Material Master → Material → Flag for Deletion → Immediately or transaction code MM06.

b)

On the selection screen, enter material T-D## and choose Enter

c)

Select the above material.

d)

Choose Save

.

.

To make sure the deletion flag works, try to perform a goods issue using transaction code MB1C for your material T-D## at plant 1000, storage location 0002 using movement type 501.

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b)

Enter movement type 501, plant 1000, storage location 0002 and press Enter.

c)

Enter your material T-D## and a quantity of 1 pc, and press Enter.

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Enter transaction code MB1C or choose Logistics → Materials Management → Inventory Management → Goods Movement → Goods Receipt → Other.

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To prevent such issues from happening, you want to use a material status to prevent the material from being used at all. Change your material T-D## by inserting an X-plant/materials status that identifies the material as obsolete. Material/plant status OB - Obsolete Materials has been created to prevent any logistics activities from happening until the material can be archived. a)

Choose Logistics → Production → Master data → Material master → Material → Change→ Immediately (MM02).

b)

Select the Basic Data 1 view.

c)

In View: Basic data 1 under General Data, in the field X-plant matl status, enter OB - Obsolete Materials.

d)

Choose Save

. Continued on next page

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4.

Do not save your entries.

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d)

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Note: This should result in a warning that the deletion indicator is set.

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a)

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Caution: Do not save your entries.

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3.

Planning has informed you that the material T-D## at plant 1000 is obsolete. Your company's procedures prevent you from immediately deleting a material master. Archiving will take place several months from now but for time being you must set the deletion flag for the material. Flag material master record T-D## for deletion.

Unit 3: Material Masters

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After applying the obsolete material status, try to receive another goods receipt to see if this will prevent possible mishaps with obsolete materials. Use transaction code MB1C for your material T-D## at plant 1000, storage location 0002 using movement type 501. Caution: Do not save your entries. Enter transaction code MB1C or choose Logistics → Materials Management → Inventory Management → Goods Movement → Goods Receipt → Other.

b)

Enter movement type 501, plant 1000, storage location 0002 and press Enter

c)

Enter your material T-D## and a quantity of 1 pc, and press Enter Note: This should result in an error message that states that the material has a status of “Obsolete Materials in plant 1000.” Do not save your entries.

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Lesson: Managing the Material Master

Lesson Summary You should now be able to: • Describe different ways to update or change the material master • Demonstrate the mass maintenance features of the material master • Describe how the material master can be updated using the request processes with interactive forms for materials management • Describe the archiving and deletion process for the material master

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Lesson: Configuration of the Material Master Lesson Overview In this lesson you will learn about the customized material master record as well as other check tables. The following aspects of the customized material master record are explained: • • • •

Screen sequence Logical screens Subscreens Influencing factors

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

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• • •

Describe the process of influencing the field characteristics of the material master Describe Process of configuring the screen layout of the material master Set up a customized material master in Customizing Test the settings by creating a material master

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As the project lead for implement material master files, you must be aware of the structural design of the object in SAP ECC. One of the business requirements your company has is to make certain fields required input before save a material master. In addition users have commented on the screen the layout of the stand SAP material master. In this lesson you will learn how to make fields in the material master required, and acquire a basic understanding of customizing the layout of the material master.

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Business Example

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Lesson: Configuration of the Material Master

Configuration Sequence for Material Master Records

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Figure 40: Configuration Sequence for Material Master Records

The abbreviations in the graphic have the following meanings:

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M = Required activity (required) O = Optional activity (optional) D = Default available for activity (default)

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• • •

You specify a material type for each material. The material type is part of the general data of a material.

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By specifying which views can be used for a material type, you determine which user departments can maintain a material with this material type.

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Control Using Material Type

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You can control the type of inventory management (quantity and/or value) for a material type depending on the plant. Price control can be defined as a default value or as a fixed value.

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You can control access protection in more detail by using the authorization group.

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Material Status The material status allows you to control the use of a material for business purposes.

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Hint: Material types that are maintained by customers can also be assigned to the transaction codes delivered by SAP. For example, go to transaction code MMR1 Material → Create specifically → Raw material in Customizing step Assign material types to special create transactions and replace material type ROH with customer-defined material ZROH. The advantage of this is that the material type does not have to be entered when the material is created.

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The material type is an influencing factor for the field selection and the customized material master.

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You can determine inconsistencies in valuation areas using the Customizing for the material type.

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Material stock accounts and consumption accounts are assigned by using valuation classes.

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Figure 41: Control Using Material Type

PLM114

Lesson: Configuration of the Material Master

The material status is defined depending on material, client, and plant. You can limit the usability of a material in different ways: • •

The material can be flagged for deletion. The material can be locked for certain business transactions by the material status for material management/production planning and control

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Figure 42: Material Status

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Hint: The more restrictive status always wins out (independent of storage location or plant).

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You can define the material status for all plants (basic data view), or separately for each plant (plant view).

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You can display whether a material is subject to restrictions, and what these restrictions are with the status information function. You can call this function when you create, display, or change a material master record. Proceed as follows: Choose Extras - Status information from any screen.

Unit 3: Material Masters

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Field Selection Follow these steps to set field selection: 1. 2. 3. 4. 5.

Determine the field selection option (hide, and so on). Determine the control string (material type, and so on). Determine the field selection group. Change the control indicator for the field selection group in the corresponding control string. Test the change.

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You can find out the table name of a field by using the technical information in the F1 help.

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In Customizing, you can use the table name to help you find the appropriate field selection group.

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Figure 43: Field Selection Procedure

PLM114

Lesson: Configuration of the Material Master

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The field selection option applies to all the fields in the field selection group (for example, all the fields are required fields).

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Hint: Always check first which fields have been assigned to a field selection group. Do not make changes without consulting the affected department.

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One or more material master fields are assigned to a field selection group.

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Figure 44: Field Selection - Field Selection Group

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Figure 45: Field Selection - Influencing Factor

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A separate control string exists for each of these influencing factors. Each position in a control string of this kind applies to a specific field selection group. The field option applies to the entire field selection group and all the master data contained in it. You generally use a reference key to specify which control list is valid for an influencing factor. You can maintain the reference key for the material type, plant, and industry sector in the settings menu. Each position in a control string defines the field selection for a group of material master record fields. In the settings menu, you can determine to which group the individual fields are assigned.

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Field selection in a material master transaction is generally determined by several control strings. The entries of all the control strings for the relevant transaction are linked to one another.

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- Hide * Display + Required entry . Optional entry

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The link rules shown above determine which fields are selected for each group of material master fields. In order of priority, the signs mean:

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Figure 46: Field Selection - Link Rules

PLM114

Lesson: Configuration of the Material Master

Customizing the Material Master You can structure the material master according to your company's requirements: • • •

You can remove screens, which are not required, from the screen sequence. You can create your own screens, by adding or deleting screen modules. You can influence individual fields in the screen modules.

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Each logical screen consists of several related field groups. In ECC these are referred to as subscreens. The fields assigned to each screen module cannot be changed in Customizing.

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Customized material master records support efficient data maintenance by letting you create entry screens that suit your company's data requirements. The material master record is a set of logical screens which appear in a specific sequence if more than one view is selected. This is referred to as a screen sequence.

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Figure 47: Customized Material Master (1)

In Customizing for the material master, you can:

F o r

Create and maintain screen sequences Maintain logical screens Maintain the order of logical screens in a screen sequence Determine which subscreens appear on which logical screens Assign influencing factors for field selection to a screen sequence Assign a user or user group to a screen sequence Preset the default organization level, default industry sector, and logical screens for a user or group of users

The views of the material master record correspond to the logical screens in Customizing. The logical screen is the visible data screen.

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There are main screens (maximum of 29), additional screens (maximum of 15) and other screens (non-configurable, for example, initial screens). The additional screens are assigned to the main screen using the PB## function codes (this corresponds to the name of the pushbutton in the Screen Painter). The secondary screens can be added to the additional data screens with automatic numbering (maximum of 15 additional screens including secondary screens).

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A screen sequence consists of logical screens (views) and secondary screens.

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Figure 48: Screen Sequence

The sequence of the screens can be specified for each screen sequence.

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You can define a screen sequence to suit your requirements.

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Figure 49: Subscreens

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Lesson: Configuration of the Material Master

A logical screen (view) consists of several screen modules. It consists of a subscreen container where you can enter several subscreens (maximum of 6). Standard screen modules (SAPLMGDI) have exactly one frame that can contain up to 10 lines and they have exactly 83 columns. You are free to choose the sequence of the screen modules. You can vary the number of subscreens for each logical screen. Subscreens from different logical screens can be grouped together on one screen. The maintenance status of the screen module fields must be the same as the maintenance status of the logical screen. You may have to extend the status of the logical screen in Customizing.

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Changes to a logical screen are saved in the screen sequence that is changed. This means that if you change the structure of MRP 1 in sequence 99, this change is only effective in sequence 99.

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When creating your own logical screens we recommend that you use the standard subscreens that are already available. You will need your own subscreens if different field groups or new fields are required. To create your own subscreens, copy standard program SAPLMGD1 to its own function group (for instructions, see the IMG). Then create the required subscreen in the new function group. Append structures have been defined in DDIC for including your own fields.

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Figure 50: Topic Summary: Customized Material Master

Unit 3: Material Masters

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You can only include fields from user-specific tables and user-specific subscreen containers in program SAPLMGMM by using modifications. Before you configure your own material master record dialogs, be sure to read the IMG.

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Lesson: Configuration of the Material Master

Setting Up Screen Sequences 1.

Set up a customized screen sequence Y# (where # equals 1 to U for groups 01 to 30) for material master maintenance. Use screen sequence 21, Std ind.(short) tab pages as a template for your screen sequence Y#, screen sequence GR ##.

2.

From the SAP Easy Access screen, choose Tools→ Customizing→ IMG → Edit project (transaction SPRO). Choose Display SAP Reference IMG (= F5). Choose Logistics general → Material master →Configuring material master records → Define structure of the data screens for each screen sequence.

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In the Screen Sequences view, select 21.

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In the dialog structure for maintaining screen sequences, data screens, and subscreens, copy screen sequence 21 with all its dependent entries to your new screen sequence Y#. Save the screen sequence.

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3.

Choose Copy As (= F6).

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Y# screen sequence group ## Choose Enter.

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5.

The data screen 29 (MRP 4) should be adjusted. Simulate the screen first, and then delete all subscreens except: 1005

Material number

2502

Control repetitive manufacturing

2504

Discontinuation control.

You should use the subscreen procurement (2484) from the data screen 27 (material requirements planning 2). Simulate your changes. Select data screen MRP 4 (screen 29) and display the subscreens. Display the subscreens by clicking Data screen view. (Leave view using Exit.) Select and delete all subscreens except1005, 2502, and 2504. Continued on next page

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Select your new screen sequence Y# and double-click on Data screens to go to the dialog structure. Select the data screen Basic data 2 (Screen: 08 ) and double-click on subscreens to go to the subscreens. Select module 2010 and choose Delete (Shift+F2). Return to the data screen view.

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4.

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Choose Save.

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Wait! Approximately 3000 dependent objects are copied.

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Overwrite the first subscreen 0001 ( = sequence number 4) with that of procurement 2484 from screen 27. Simulate the changed screen: Data screen view. Save your changes. 6.

Delete data screen 27 (MRP 2) from your screen sequence. Go back to the Data screens view again, select the MRP 2 (screen 27) screen and delete it with all its dependent entries. Approximately 92 dependent objects are deleted. Choose Save.

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1. Screen

Basic data

2. Screen

MRP 4

3. Screen

Work scheduling

4. Screen

Storage location stock

5. Screen

Classification

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Change your screen sequence ## so that the data screens appear in the following sequence:

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Work scheduling

160 –> 12

Storage location stock

280 –> 13

Classification

30 –> 14

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140 –> 11

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Change the order according to the task.

Choose Sort Main Screens (renumbering) and save the new sequence. 8.

The screen sequence should be effective for your user. Define a screen reference for your user and determine a new list of influencing factors.

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Under Maintain Order of Main and Additional Screens, select your screen sequence number and click the Details icon or double-click on the new screen sequence.

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The rest of the sequence following these data screens should remain unchanged.

MRP 4

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7.

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Lesson: Configuration of the Material Master

In Screen sequences for users / material types / transactions /assign industry sectors, display the step Screen reference user. Maintain a new entry. Use the user name that you used to log on to the system and assign an abbreviation to it. For example, Y# (the same abbreviation as the new screen sequence). Choose Save.

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01

ScrRef.User

The user reference you created (F4 help if saved previously)

ScrRef. matl type

*

ScrRef. industry

*

Scr.sq

The screen sequence number you created (input help)

Save your changes.

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9.

Check your settings by displaying material master T-F1##.

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General Check Tables for the Material Master Record

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Check your settings as described in the exercise.

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SRef: trans.

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Under Controlling screen sequence, create a new string (New entries) or copy the existing control string with the screen sequence 21 as a template, and enter the following values:

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Figure 51: Other Check Tables for the Material Master Record

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The material master contains a series of fields that are checked against other tables. These tables must be set up before you create material master records. Hint: In addition to the check tables listed above, there are also check tables for which no hard check is performed. In other words you need not necessarily make an entry in Customizing. Here you can make entries that were not made available previously. However, these entries do not update the Customizing table: For example basic material in basic data 2.

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Lesson: Configuration of the Material Master

Exercise 4: Material Types, Field Control and Material Status Exercise Objectives After completing this exercise, you will be able to: • Create a new material type • Set up a new field selection for your new material type and a new material status

Business Example

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1.

As a template, use the material type for the finished product FERT. Change the description of a new material type in group ##. Save the newly created material type before processing further.

2.

Note the following specifications for the new material type:

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- External and internal purchase orders are allowed. - Externally assigned material numbers should not be checked against a number range.

F o r

For materials of this material type, the following views are allowed to be maintained: Work scheduling, accounting, classification, MRP, purchasing, costing, basic data, storage, plant stocks, and storage location stocks. In all plants (valuation areas) the quantities and values for materials of this material type should be updated. The valuation of all materials of this material type should be binding (that means not changeable) according to the valuation procedure moving average price.

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- Cost estimate with quantity structure (BOM, routing) is allowed.

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Account assignment is to be according to account category reference 0009, the same as for material type FERT.

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Add a new material type MA## (## = group number).

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Task 1:

F o r

A new material type is needed in plant 1000. Because the old material number from the legacy system is very important, it is to be turned into a required entry in SAP ECC. A new material status should only allow the maintenance of BOMs with a warning message.

Unit 3: Material Masters

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Task 2: Check the number assignment for materials of your material type. 1.

Make sure that the number assignment for materials of your material type MA## uses the same number range group as for the template material type FERT.

Task 3:

Old material number

(MARA-BISMT)

Material status (cross-plant)

(MARA-MSTAE)

3.

What other fields belong to these groups?

4.

Copy the field selection reference Z## with reference FERT, and define the fields mentioned above as required fields at the same time.

5.

Now assign the field selection reference Z## to your material type MA##.

6.

Test your setting by creating a material T-A## with material type MA## (basic data views 1 and 2 only and work scheduling for plant 1000). The old material number for this material is your choice. Use material status 02 on valid-from date .

F o r

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When you create a new material master record using the copy function, are the contents of the fields copied?

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2.

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To which field selection group do these fields belong?

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1.

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You can see the data for the individual fields that you want to change by using the field help (F1 or Help icon) and choosing the Technical Information button or the Technical Information icon.

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C S C

Field name complete

b y

Material description

F o r

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Material type MA## is used for the finished products that are copied from an external system. The following material fields are to be required fields for material type MA##:

PLM114

Lesson: Configuration of the Material Master

Solution 4: Material Types, Field Control and Material Status Task 1: Add a new material type MA## (## = group number). 1.

As a template, use the material type for the finished product FERT. Change the description of a new material type in group ##. Save the newly created material type before processing further. Account assignment is to be according to account category reference 0009, the same as for material type FERT.

o n l y

Creating a new material type: From the SAP Easy Access screen, choose Tools→ Customizing→ IMG → Edit project (SPRO).

F o r

Choose Display SAP Reference IMG (F5).

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a)

Choose Logistics general → Material master →Basic settings → Material types → Define attributes of material types.

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Select material type FERT. Click Copy (F6).

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Note the following specifications for the new material type:

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2.

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For materials of this material type, the following views are allowed to be maintained: Work scheduling, accounting, classification, MRP, purchasing, costing, basic data, storage, plant stocks, and storage location stocks.

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In all plants (valuation areas) the quantities and values for materials of this material type should be updated.

- Cost estimate with quantity structure (BOM, routing) is allowed.

b y

- Externally assigned material numbers should not be checked against a number range.

F o r

- External and internal purchase orders are allowed.

Unit 3: Material Masters

PLM114

The valuation of all materials of this material type should be binding (that means not changeable) according to the valuation procedure moving average price. a)

Check all points according to the task set, and change if necessary: • • • •

F o r

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• •

Name Description Internal/external order = 2 User department (like FERT, but without forecast, QM, warehouse management, and sales) Quantity/value update: 1 flag each Valuation: Price ctrl mandatory

Task 2: Check the number assignment for materials of your material type.

C S C

Make sure that the number assignment for materials of your material type MA## uses the same number range group as for the template material type FERT.

C S C

You may want to display the assigned number ranges here, too: choose Maintain (Shift+F5).

Your material type should already be assigned to group 1 (the same as FERT). If not, select material type MA##, select the group to which material type FERT belongs and choose Assign element / group (F5).

b y

Choose Change groups (F6).

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In Customizing, choose Logistics general → Material master → Basic settings → Material types → Define number range for each material type.

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b y

a)

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Lesson: Configuration of the Material Master

Task 3: Material type MA## is used for the finished products that are copied from an external system. The following material fields are to be required fields for material type MA##: Material description

Field name complete

Old material number

(MARA-BISMT)

Material status (cross-plant)

(MARA-MSTAE)

1.

To which field selection group do these fields belong? Setting fields as required entry: First you determine the numbers of the field selection groups. For this, choose Logistics general → Material master → Field selection: Assign fields to field selection groups in Customizing.

b y

Field selection groups (search by field name) MARA-BISMT: 11 2.

When you create a new material master record using the copy function, are the contents of the fields copied?

Select the field and click on Detail or double-click on the field names. 3.

What other fields belong to these groups? a)

Display the field selection maintenance in field group maintenance.

o n l y

F o r

Find these fields in the Field groups table: MARA-BISMT: 11 MARA-MSTAE: 155 Choose the Field selection maintenance icon (or corresponding pushbutton in the right-hand column). There are no more fields for field selection group 11. Group 155 includes the field MARA-MSTDE (date from which the cross-plant material status is valid). Continued on next page

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The contents of the fields is copied on creation, because the reference indicator (default field content) is set.

b y

a)

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MARA-MSTAE: 155

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a)

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You can see the data for the individual fields that you want to change by using the field help (F1 or Help icon) and choosing the Technical Information button or the Technical Information icon.

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4.

PLM114

Copy the field selection reference Z## with reference FERT, and define the fields mentioned above as required fields at the same time. a)

In Customizing, use the menu path Logistics general → Material master → Field Selection → Maintain Field Selection for Data Screens or click the Field sel. maint. button in the previous exercise.

b)

Copy a field selection reference with the new name Z## and set it up so that the fields named above are displayed as required entries. As a template, use the field selection reference for the finished product FERT.

C S C

Z##

Line 11

Required entry

Line 155

Required entry

Enter and save.

b y

5.

Now assign the field selection reference Z## to your material type MA##.

In Customizing, choose Logistics general → Material master → Basic settings → Material Types → Define attributes of material types and then Change.

u s e

The field reference is Z## instead of FERT.

b y

6.

Test your setting by creating a material T-A## with material type MA## (basic data views 1 and 2 only and work scheduling for plant 1000). The old material number for this material is your choice. Use material status 02 on valid-from date .

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Choose Logistics → Production → Master Data → Material Master → Material → Create (general) → Immediately.

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a)

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Assign the field selection reference Z## to the material type MA##, while you assign the field selection Z## to the material type.

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a)

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Name

F o r

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Select the line FERT and copy it to Z## (choose Edit → Copy as, or corresponding pushbutton, or F6).

PLM114

Lesson: Configuration of the Material Master

Lesson Summary You should now be able to: • Describe the process of influencing the field characteristics of the material master • Describe Process of configuring the screen layout of the material master • Set up a customized material master in Customizing • Test the settings by creating a material master

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Unit Summary

PLM114

Unit Summary

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You should now be able to: • Describe the organizational layout of the material master • List the prerequisites to creating material masters • Use various methods to create material masters • Describe the request process with interactive forms and explain how it might benefit your business • Describe how the material master can use classification to include company-specific fields • Describe how classification can be used for batch management of inventory • Describe how classification can be used for variant configuration • Describe different ways to update or change the material master • Demonstrate the mass maintenance features of the material master • Describe how the material master can be updated using the request processes with interactive forms for materials management • Describe the archiving and deletion process for the material master • Describe the process of influencing the field characteristics of the material master • Describe Process of configuring the screen layout of the material master • Set up a customized material master in Customizing • Test the settings by creating a material master

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Test Your Knowledge

Test Your Knowledge 1.

The classification system, all classes, characteristics, and characteristic values are predefined by SAP and delivered with the system and cannot be changed by users. Determine whether this statement is true or false.

□ □ 2.

True False

Only material master records can be classified using the classification system. Determine whether this statement is true or false.

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A batch is a unique homogeneous subset of a material, which is not reproducible.

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3.

True False

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□ □

Determine whether this statement is true or false.

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□ □

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Variant configuration uses classification to select specific items on the bill of material and the corresponding operation on the routing for products that have many different options.

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5.

True False

F o r

Determine whether this statement is true or false.

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A new material type can be created by simply clicking New Entries and entering the data.

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□ □

b y

Determine whether this statement is true or false.

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4.

True False

Test Your Knowledge

6.

PLM114

Which of the following can be used to influence the screen sequence and attributes (required, visible, hidden) of the material master record. Choose the correct answer(s).

□ □ □ □ □

A B C D E

User ID Material type Plant Industry Transaction

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Test Your Knowledge

Answers 1.

The classification system, all classes, characteristics, and characteristic values are predefined by SAP and delivered with the system and cannot be changed by users. Answer: False The classification system is a user-defined way for companies to create their own classes, characteristics, and characteristic values.

2.

Only material master records can be classified using the classification system.

o n l y

3.

A batch is a unique homogeneous subset of a material, which is not reproducible.

b y

Answer: True

u s e

Variant configuration uses classification to select specific items on the bill of material and the corresponding operation on the routing for products that have many different options.

F o r

5.

A new material type can be created by simply clicking New Entries and entering the data. Answer: False A new material type can be created only by copying an existing material type and making changes. There are so many underlying dependencies on a material type that they must be copied to be sure all of the dependencies are also copied.

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Variant configuration uses class type 300 and object dependencies in the BOM and routing to select specific items on the bill of material and the corresponding operation on the routing for products that have many different options.

C S C

Answer: True

b y

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4.

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Because each batch has unique characteristic values, it is a unique subset of a material that cannot be reproduced.

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C S C

In addition to material master records, the classification system can be used to classify routings, work centers, PRTs, and documents.

F o r

Answer: False

Test Your Knowledge

6.

PLM114

Which of the following can be used to influence the screen sequence and attributes (required, visible, hidden) of the material master record. Answer: B, C, D, E Material type, plant, industry, and transaction as well as procurement indicator can all be influencing factors in controlling the screen sequence and field attributes of a material master record.

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Unit 4 Bills of Material Unit Overview

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C S C

After completing this unit, you will be able to:

F o r

Lesson: Overview of the Bill of Material .....................................132 Exercise 5: BOM Basics: Display ........................................143 Lesson: Managing Bills of Material ...........................................147 Exercise 6: Changing Bills of Material ...................................161 Lesson: BOM Reporting .......................................................178 Exercise 7: Multilevel BOM Reporting ...................................183 Lesson: Configuration of the Bill of Material.................................189 Exercise 8: Bill of Material Configuration................................197

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Unit Contents

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• • •

b y

i n t e r n a l

• •

Describe the organizational layout of the bill of material Demonstrate the validity process and changing an active bill of material Demonstrate how engineering change management (ECM) affects the validity of a bill of material Describe the process of archiving and deleting a bill of material Demonstrate the various bill of material reports that are available to individuals Demonstrate the comparative reporting tools for bills of material Describe the configuration activities surrounding the BOM header Describe the configuration activities surrounding the BOM items

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• • •

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Unit Objectives

F o r

This unit introduces the basic concepts of the SAP ERP bill of material. You will be instructed on the creation, maintenance, reporting, and configuration of the bill of material. You will also execute various transactions to manage the process surrounding its life cycle. Several advanced topics will be covered in another unit.

Unit 4: Bills of Material

PLM114

Lesson: Overview of the Bill of Material Lesson Overview This lesson introduces the bill of material.

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

Describe the organizational layout of the bill of material

Business Example

o n l y

C S C

b y

u s e

b y

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BOMs contain important 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).

i n t e r n a l

BOM Overview and Usage

F o r

As the project lead for implementing bills of material, you must be aware of the structural design of the object in SAP ECC. In doing so, you will learn how the bill of material is structured to integrate with several business areas in your company. Your company has requirements to use bills of material for costing, engineering and production. In addition your planners want to know what features they can use to model the use of certain materials in specific manufacturing processes.

C S C

F o r

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Figure 52: Bill of Material Definition

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Lesson: Overview of the Bill of Material

BOMs can be found in various forms wherever finished products or semifinished products are produced from several component parts or materials. Depending on the industry sector, they may be called: • •

Recipe List of ingredients

b y

u s e

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C S C

Component, part, and item are all synonyms.

b y

Single-level BOM A single-level BOM is a set of all the components that represent one or more assemblies.

u s e

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.

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F o r

Figure 53: Terminology

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

C S C

b y

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.

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

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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.

C S C

• • •

b y

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The BOM is also used:

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•

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Engineering design creates BOMs. You can create BOMs in ECC using a computer-aided drawing (CAD) program and a CAD interface.

F o r

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Figure 54: BOM Integration

Lesson: Overview of the Bill of Material

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PLM114

Figure 55: BOM Categories

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b y

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.

u s e

Order BOMs are used to produce a product for a specific sales order.

i n t e r n a l

C S C

Functional location BOMs are used in plant maintenance to link equipment to specific locations.

b y

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.

u s e

Material BOMs are used in SCM to represent the structure of products that are manufactured.

i n t e r n a l

BOM categories define the connection to an object.

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b y

The bill of material usage allows you to create separate BOMs for the various areas within the company, for example, engineering or production.

i n t e r n a l

b y

Of course, you can also work with just one BOM for all areas by using the item status to cover all possible differences.

C S C

each BOM with a separate internal number for each usage.

When creating BOMs with different usages for one material, the system saves

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The costing BOM is the basis for the automatic calculation of the material usage costs of a product.

F o r

•

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.

u s e

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•

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Figure 56: BOM Usage

PLM114

Lesson: Overview of the Bill of Material

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F o r

C S C

Examples:

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.

o n l y

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F o r

BOM B A BOM with status 2 cannot be exploded in MRP or released for a planned order.

You can define item status fields as required, optional, or disallowed for a specific application area in your company.

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BOM A A BOM with status 1 can be exploded in MRP and released for a planned order.

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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.

i n t e r n a l

Figure 57: BOM Status

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BOM Prerequisites Before you create a BOM, you should answer these questions.

o n l y

Does a material master exist for the BOM header? What is the BOM going to be used for? Is this material type allowed in BOMs? In which plant is the BOM required? When does the BOM need to become effective? Are change documents necessary? Does the material belong to a BOM group? What status does the BOM have? Are there default values?

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• • • • • • • • •

Bill of Material: Structure

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F o r

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

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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.

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Figure 58: BOM Structure

Lesson: Overview of the Bill of Material

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Figure 59: Subitems

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The sum of the subitem quantities replaces the item quantity.

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A subitem has no control functions in the BOM.

Assignments to operations only at item level Waste is calculated only at item level

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i n t e r n a l

• •

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This means, for example:

i n t e r n a l

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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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.

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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.

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Figure 60: Units of Measure

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Figure 61: Low-Level Coding

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Lesson: Overview of the Bill of Material

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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Lesson: Overview of the Bill of Material

Exercise 5: BOM Basics: Display Exercise Objectives After completing this exercise, you will be able to: • Display a standard bill of material • Navigate the BOM structure

Business Example As a planner, you must be able to display the material BOM. This will provide insight to the components required in the manufacturing process.

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C S C

2.

You should see the bill of material categories that the system allows. What are they?

b y

3.

Display the material BOM for pump T-F1## in plant 1000. The BOM usage is 1(Production).

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4.

What is the component number of item 0010?

5.

What are the component quantity and unit of measure?

6.

Is this component a stock item?

7.

Is this component in the BOM valid on January 1, 2006?

8.

Does a BOM exist for this component?

9.

Display the material BOM for component T-B3##.

u s e

Go to the bill of material menu.

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10. What is the valid-to date of this bill of material? 11. What are the base quantity and unit of measure of this bill of material?

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1.

i n t e r n a l

Navigate the bill of material for pump T-F1## to become familiar with the SAP ECC structure.

F o r

Task:

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Solution 5: BOM Basics: Display Task: Navigate the bill of material for pump T-F1## to become familiar with the SAP ECC structure. 1.

Go to the bill of material menu. a)

2.

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material.

You should see the bill of material categories that the system allows. What are they?

Functional location BOM

Document BOM Equipment BOM Order BOM

b y

WBS BOM Display the material BOM for pump T-F1## in plant 1000. The BOM usage is 1(Production).

Field

Value

Material

T-F1##

Plant

1000

BOM Usage

1

C S C

o n l y

F o r

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Display.

b y

i n t e r n a l

a)

Enter data from the above table and choose 4.

What is the component number of item 0010? a)

5. 6.

T-B1##

What are the component quantity and unit of measure? a)

1 PC

Is this component a stock item? a)

Yes (item category = L) Continued on next page

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u s e

3.

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Material BOM

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The bill of material categories are:

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a)

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Lesson: Overview of the Bill of Material

7.

Is this component in the BOM valid on January 1, 2006? a)

8.

Does a BOM exist for this component? a)

9.

Yes (effective until 31.12.9999) Yes (assembly indicator is set)

Display the material BOM for component T-B3##. a)

You can display it in the same way as the previous task or, in the General Item overview screen for material T-F1##, double-click on the assembly indicator in the A column for T-B3# and choose Continue.

a)

Select header then Adm. Data tab.

b)

The valid-to date is 31.12.9999.

F o r

o n l y

10. What is the valid-to date of this bill of material?

Select the Quants/Long txt tab.

b)

1 Pc

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a)

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11. What are the base quantity and unit of measure of this bill of material?

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Lesson Summary You should now be able to: • Describe the organizational layout of the bill of material

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Lesson: Managing Bills of Material

Lesson: Managing Bills of Material Lesson Overview Bills of material must be maintained as accurately as possible. This lesson discusses the methods for creating and changing BOMs. Other topics include validity and engineering change management.

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

•

Demonstrate the validity process and changing an active bill of material Demonstrate how engineering change management (ECM) affects the validity of a bill of material Describe the process of archiving and deleting a bill of material

u s e

C S C

u s e

b y

As an engineer/planner who is responsible for maintaining bills of material, you must be aware of the options surrounding updating the bills of material. The products you are responsible for are constantly undergoing changes and improvements. Your company has decided to use the same material number, therefore you must reflect the changes in the bills of material.

Validity of the Bill of Material

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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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Business Example

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• •

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There must be a plant view for the BOM header and all the item materials in each plant that the BOM is assigned to.

u s e

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.

The area of validity defines which plants can use a bill of material.

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Figure 62: Validity: Area (1)

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Lesson: Managing Bills of Material

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Planning of material requirements Creation of routings

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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.

C S C

i n t e r n a l

• •

u s e

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:

Material BOMs can be effective on different organizational levels.

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Figure 63: Validity: Area (2)

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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.

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Figure 64: Validity: Area (3)

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Figure 65: 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: 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.

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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.

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Each BOM item must have anitem 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.

F o r

BOM Management - Item Details

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Figure 66: Item Categories

The item category provides answers the following questions, for example: • • • • •

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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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The component is procured directly for the production order. Purchase requisitions are created automatically.

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Using the price data (purchasing data) entered, the system calculates the release strategy. The material group is necessary for creating a purchase requisition.

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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.

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Figure 67: Non-Stock Items / Item Category: N

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Figure 68: Variable-Size Item/Item Category R

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Lesson: Managing Bills of Material

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

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F o r

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If you want to document the product or a component, choose item category D.

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Prerequisites for documenting a product or component are as follows:

F o r

A document info record must exist for the document, and be 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.

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Figure 69: Document Item/Item Category D

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Figure 70: Class Item/Item Category K

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You can use classes that have materials or documents classified in them (with class types 200, 201, and 300) as class items.

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When you configure a BOM, the class node can be replaced by a specific material or document.

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

C S C

F o r

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Figure 71: Recursion

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:

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Lesson: Managing Bills of Material

Error: BOM is recursive In exceptional cases, recursion can be recognized only 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.

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F o r

C S C

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Figure 72: Item Control Indicators

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Screens: S = Status/lng text You can set most control indicators in the material master. Most are not copied to the BOM.

F o r

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

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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.

C S C

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B = Basic data

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The various item categories can be combined with various indicators. Thus special procedures can be controlled.

Unit 4: Bills of Material

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Overview of ECM in Bills of Material

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F o r

C S C

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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.

b y

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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.

F o r

You can use engineering change management to fulfill your legal obligations to document changes.

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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.

C S C

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.

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Engineering change management is a central logistics function that can be used to change various master data and document the changes.

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Figure 73: Why Use Engineering Change Management?

PLM114

Lesson: Managing Bills of Material

o n l y

F o r

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b y

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.

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F o r

Engineering change management in the SAP system enables you to document changes completely, to cover product liability requirements, for example.

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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.

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Changes with history must be documented because they take place during production, for example.

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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.

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Changes without history do not have to be documented because they take place during the development stage of the product, for example.

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Figure 74: Engineering Change Management

Unit 4: Bills of Material

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o n l y

F o r

C S C

b y

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.

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C S C

Alternative dates allow you to control the valid-from date for individual objects more exactly.

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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.

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You determine which objects can be changed with the change master record by selecting the object types.

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Figure 75: Structure of Change Master Record

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Lesson: Managing Bills of Material

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•

b y

•

– 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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•

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

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Figure 76: BOM - Validity Period of Elements

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Deleting the Bill of Material Bills of material can be deleted in several ways. •

You can delete bills of material using: – –

The deletion function Deletion flags

•

Using the delete function, the BOM is removed from the system immediately. If engineering change management is used, the BOM is deleted 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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Before deleting a BOM, the system checks for:

F o r

•

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. You can find out more about SAP document management in the PLM120 course.

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•

C S C

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.

b y

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.

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Deletion at header level removes the entire BOM, whereas deletion at item level removes only the specified item.

i n t e r n a l

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– Without history – With history using engineering change management Authorization groups control who can delete a bill of material

C S C

•

– Delete the entire BOM – Delete individual items BOMs can be deleted:

b y

You can:

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•

PLM114

Lesson: Managing Bills of Material

Exercise 6: Changing Bills of Material Exercise Objectives After completing this exercise, you will be able to: • Create a group BOM • Assign the BOM to a plant • Change a bill of material

Business Example

o n l y

Task 1:

i n t e r n a l

C S C

Create a bill of material. 1.

Create a group BOM for material T-F## (## = group number).

i n t e r n a l

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.

3.

Enter the following components in the general item overview for BOM T-F##: Item no.

Item cat.

Component

Quantity

Sort string

10

L

100-100

1

A5

20

L

100-200

2

A1

30

L

100-300

1

A3

Save the BOM and display the header using the transaction Change material BOM. Continued on next page

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User Entry

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Field

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Note the following when you create a group BOM:

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Your company's BOMs are similar across multiple plants. You want to create a group BOM as a template that can then be copied or assigned to the appropriate plants as necessary.

Unit 4: Bills of Material

PLM114

Go to the BOM header and make a note of the internal BOM number: _______________ 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? _________

5.

Return to the BOM and save your work.

Task 2:

2.

Why can you not assign it to plant 1100?

3.

Go to the BOM header for plant 1000.

b y

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Assign the group BOM to plants 1000 and 1100.

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1.

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o n l y

Create and change plant validity.

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What is the internal BOM number? _______________ Delete the plant assignment (plant 1000).

5.

Create a plant -specific BOM for T-F## in plant 1000. Use the group BOM as a template. Make the following plant-specific changes: Change the quantity of item 20 from 2 to 1. Maintain item 20 with spare part indicator “A”

o n l y

F o r

Sort the BOM according to the sort string.

Task 3: Extend your plant-specific BOM T-F## in plant 1000. 1.

Change BOM T-F## in plant 1000.

2.

Add component 100-600.

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4.

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Why? _______________

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Lesson: Managing Bills of Material

Item no.

Item cat.

Component

Quantity

40

L

100-600

2

The two 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.

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u s e

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

Add a variable sized item, 100-700, with the dimensions below. Item no.

Item cat.

Component

Quantity

60

R

100-700

1 piece

200 mm

Size 2

300 mm

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Size 1

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Item cat.

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F o r

Item no.

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4.

Add a non-stock item by entering the data below.

F o r

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3.

Note the calculated variable-size item quantity. Change variable size from 300 to 400mm. Get the system to recalculate the variable-size item quantity. 5.

Add bulk material component 100-130. Item no.

Item cat.

Component

Quantity

70

L

100-130

10

Continued on next page

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6.

7.

PLM114

Add drawing document T-F1## to the BOM and save. Item no. Item cat.

Document

Typ

DPt

Vs

Quantity

80

T-F1##

DRW

000

00

1

D

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

Task 4:

Use your Engineering Change Number, ECN## to change the BOM for T-F## by replacing 100-100 with T-B##.

b y

o n l y

C S C

2. 3.

Check your BOM for T-F## to view the results.

b y

i n t e r n a l

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u s e

First, create an Engineering Change Number ECN## that is valid for changing material masters, BOM's, and routings, and has a validity date 2 months from today.

i n t e r n a l

1.

F o r

In two months, component 100-100 will be replaced by T-B##. Change the BOM with history to take place at the appropriate time.

C S C

F o r

o n l y

164

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2006/Q2

PLM114

Lesson: Managing Bills of Material

Solution 6: Changing Bills of Material Task 1: Create a bill of material. 1.

Create a group BOM for material T-F## (## = group number).

User Entry

Plant

group BOM has no entry for plant

Usage

1 (Production)

Alternative

No entry

Valid from

Today's date

b)

Enter the data from the table below.

Material

T-F##

Plant



Usage

1

Valid from

Today's date

b y

User Entry

Which system message do you get, and why? Ensure no error messages appear. W: Group BOM The warning message regarding group BOMs can be deactivated from SAP R/3 4.7 onwards. Choose Enter

3.

to continue.

Enter the following components in the general item overview for BOM T-F##:

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165

o n l y

a)

F o r

.

C S C

2.

Choose Enter

b y

c)

u s e

Field

u s e

Choose Logistics → Production → Master data → Bills of material → Bill of material → Material BOM → Create .

i n t e r n a l

a)

i n t e r n a l

C S C

Field

F o r

o n l y

Note the following when you create a group BOM:

Unit 4: Bills of Material

PLM114

Item no.

Item cat.

Component

Quantity

Sort string

10

L

100-100

1

A5

20

L

100-200

2

A1

30

L

100-300

1

A3

Save the BOM and display the header using the transaction Change material BOM.

a)

In the general item overview, enter the data from the table above.

b)

Save your BOM by choosing

c)

From the Create material BOM: Initial screen, choose Material BOM → Change.

.

C S C

b y

d)

. The BOM number is displayed in the Select the Header icon BOM field under the material number. BOM Number: ___________________

u s e

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.

i n t e r n a l

Choose the

button.

Select component 100-100 and choose Environment → Display Material → Basic data or double-click on the material number.

F o r

5.

In the material master Basic Data 1 view, you can see that the material group is 001 (Metal processing).

Return to the BOM and save your work. a)

Green arrow back

b)

Choose Save .

to return to the BOM.

Continued on next page

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© 2006 SAP AG. All rights reserved.

2006/Q2

o n l y

b)

C S C

a)

b y

What is the name of the material group? _________

u s e

4.

i n t e r n a l

Select Enter twice to access your BOM in change mode.

F o r

o n l y

Go to the BOM header and make a note of the internal BOM number: _______________

PLM114

Lesson: Managing Bills of Material

Task 2: Create and change plant validity. 1.

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

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Plant assignment → Create.

b)

Enter the material number and BOM usage = 1. Do not enter the plant in the top portion of the screen. Enter the plant in the Assign to to section and press Enter

c)

Why can you not assign it to plant 1100?

C S C

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

b y

Answer: If you try to assign to plant 1100, you will receive a message: Material T-F## is not maintained in plant 1100.

i n t e r n a l

3.

Select the checkbox next to the plant and choose Save.

F o r

o n l y

2.

.

a)

Why? _______________ Choose Logistics → Production → Master data → Bills of material → Bill of material → Material BOM → Display.

u s e

The internal BOM number in plant 1000 is the same as the number from exercise step 1-2. A reference has been created. The BOM structure is saved under one number in the system.

b y

C S C

i n t e r n a l

b)

u s e

Choose Header .

F o r

o n l y

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Unit 4: Bills of Material

4.

PLM114

Delete the plant assignment (plant 1000). a)

Change the plant assignment: Logistics → Production → Master data → Bills of material → Bill of material → Material BOM → Plant assignment → Change.

b)

Enter the data from the table below. Field

Value

Material

T-F##

Plant



Usage

1

o n l y

C S C

d)

Display all assignments by choosing the All Allocs to BOM button. Select and delete the assignment to plant 1000 by choosing the Delete allocation button.

b y

5.

Go back to the Current allocations and choose Save .

Create a plant -specific BOM for T-F## in plant 1000. Use the group BOM as a template. Make the following plant-specific changes:

u s e

u s e

Change the quantity of item 20 from 2 to 1.

i n t e r n a l

c)

F o r

Choose Enter.

b y

i n t e r n a l

Maintain item 20 with spare part indicator “A”

C S C

F o r

o n l y

Continued on next page

168

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2006/Q2

PLM114

Lesson: Managing Bills of Material

Sort the BOM according to the sort string. a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create. Enter the data from the table below. Field

Value

Material

T-F##

Plant

1000

Usage

1

Valid from

Today's date

o n l y

or press F7.

In the Copy From.. dialog box, enter the material T-F## and BOM

C S C

.

b y

Hint: Do not enter the plant in the copy from box. Select all of the components to copy and press the Copy Make the following changes: Change the quantity of item 20 from 2 to 1.

d)

Save the BOM by choosing Save

o n l y

i n t e r n a l

to Sort the BOM according to the sort string. Choose Back return the General item Overview screen. Choose Edit → Sort → Sort by Sort string.

C S C

F o r

c)

.

Continued on next page

2006/Q2

b y

Maintain item 20 with spare part indicator “A”. Double-click in the item number to access the item details. Select the Status/Lng Text tab. Enter A in the spare part indicator field.

u s e

u s e

b)

icon again.

i n t e r n a l

Usage 1 and choose Enter

F o r

Select the copy from icon

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Unit 4: Bills of Material

PLM114

Task 3: Extend your plant-specific BOM T-F## in plant 1000. Change BOM T-F## in plant 1000. a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change.

b)

Enter the data from the table below.

c)

C S C

b y

Value

Material

T-F##

Plant

1000

BOM Usage

1

Choose Enter

.

i n t e r n a l

2.

Field

F o r

o n l y

1.

Add component 100-600. Item no.

Item cat.

Component

Quantity

40

L

100-600

2

b y

i n t e r n a l

The two support bases should be assembled at the front and the back of the pump.

u s e

u s e

The two support bases are mounted on the pump.

C S C

F o r

o n l y

Continued on next page

170

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2006/Q2

PLM114

Lesson: Managing Bills of Material

Create subitems for this. a) Item no.

Item cat.

Component

Quantity

40

L

100-600

2

Select item 40 and choose the Sub-items button. Installation point

Sub-item qty Sub-item text

0001

Front of pump

2

0002

Back of pump

1

Note: The item quantity is changed from 2 PCS to 3 PCS and a message is displayed.

C S C

i n t e r n a l

Green arrow back

or press F3.

b y

Note: Quantity is 3 and grayed out.

Item no.

Item cat.

50

N

Component

Quantity 1

One non-stock item

Purchasing org.

1000

Price

10 EUR

C S C

Item text

b y

i n t e r n a l

Add a non-stock item by entering the data below.

u s e

u s e

3.

F o r

o n l y

SubI

F o r

o n l y

Continued on next page

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Unit 4: Bills of Material

PLM114

Item text

One non-stock item

Purchasing group

000

Cost element

415000

Material group

Metal processing

a)

Enter data from the table below. Item no.

Item cat.

50

N

b)

1

.

A detailed screen will appear. Enter Copper Plated Pressure Plate in the Item text: Line 1 field. Choose Enter

C S C

b y

u s e

Field

Value

Purchasing organization

1000

Price

10 EUR

Purchasing group

000 Chef, H.

Cost element

415000

Material group

001 (Metal processing)

b y

.

C S C

Add a variable sized item, 100-700, with the dimensions below. Item no.

Item cat.

Component

Quantity

60

R

100-700

1 piece

Size 1

200 mm

Size 2

300 mm

o n l y

F o r

u s e

i n t e r n a l

A detailed purchasing screen in now displayed. Enter data as specified in the table below.

Press Enter 4.

.

Note the calculated variable-size item quantity. Change variable size from 300 to 400mm.

Continued on next page

172

© 2006 SAP AG. All rights reserved.

i n t e r n a l

c)

Quantity

F o r

o n l y

Choose Enter

Component

2006/Q2

PLM114

Lesson: Managing Bills of Material

Get the system to recalculate the variable-size item quantity. a)

Enter the following in the General Item Overview. Item no.

Item cat.

Component

Quantity

60

R

100-700

1 piece

The screen variable-size item data is displayed. Enter the sizes below: Size 1:

200 mm

Size 2:

300 mm

F o r

o n l y

Choose Enter. The Qty Var-sz Item is calculated to 0.06 M2.

C S C

Variable size item quantity:

b y

b)

0.080 m2

Change size from 2 to 400mm and press ENTER.

u s e

C S C

i n t e r n a l

Add bulk material component 100-130.

b y

5.

u s e

Note the message and that the variable quantity has not been recalculated. To recalculate the variable quantity, delete the existing value (0.06) and press ENTER. The variable quantity is recalculated to 0.08 M2.

i n t e r n a l

Warning message:Delete variable size item quantity!

F o r

o n l y

Continued on next page

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PLM114

Item no.

Item cat.

Component

Quantity

70

L

100-130

10

C S C

b y

Item cat.

Component

Quantity

70

L

100-130

10

b)

Select item and choose Item

or double-click on Item. 70.

c)

Select the Status/lng text tab page.

d)

Select the Bulk material indicator (bottom right).

e)

Remove the CostingRelevancy indicator.

f)

Arrow back or press F3.

Add drawing document T-F1## to the BOM and save. Item no. Item cat.

Document

Typ

DPt

Vs

Quantity

80

T-F1##

DRW

000

00

1

a)

D

u s e

u s e

Item no.

Select the Document tab page.

Document

Typ

DPt

Vs

Quantity

80

D

T-F1##

DRW

000

00

1

Choose Save

.

o n l y

F o r

Item cat.

Display your BOM, T-F##, with 15 as the required quantity. Who created the BOM? _________________

Continued on next page

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© 2006 SAP AG. All rights reserved.

C S C

7.

Item no.

b y

i n t e r n a l

Enter data below:

b)

i n t e r n a l

6.

Enter the data below:

F o r

o n l y

a)

2006/Q2

PLM114

Lesson: Managing Bills of Material

On what date? ________________ a)

Display material BOM by choosing Logistics → Production → Master Data → Bills of Material → Bill of material → Material BOM → Display . Field

Value

Material

T-F##

Required quantity

15

(bottom line)

From the Header, choose the Administrative data tab page.

In two months, component 100-100 will be replaced by T-B##. Change the BOM with history to take place at the appropriate time.

Enter ECN## as the Change Number. Be sure the Change Master and Without Release Key indicators both default and click Enter .

c)

Enter the description GR## ECN, a valid from date two months from today, and Change no. status 01 and click Enter .

d)

Select Object types and set the Actv. indicator for Bill of Material, Task List, and Material. Click Save

u s e

i n t e r n a l

.

F o r

Use your Engineering Change Number, ECN## to change the BOM for T-F## by replacing 100-100 with T-B##. a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change or use transaction code CS02.

b)

Enter the material T-B##, plant 1000, usage 1, change number ECN##, and choose Enter .

c)

Hit enter to work through the warning.

d)

Replace component 100-100 with T-B## and Save. Continued on next page

2006/Q2

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175

o n l y

2.

C S C

b)

b y

Use the menu path Cross-Application Components → Engineering Change Management → Change Number → Create or transaction code CC01.

u s e

a)

b y

C S C

First, create an Engineering Change Number ECN## that is valid for changing material masters, BOM's, and routings, and has a validity date 2 months from today.

i n t e r n a l

1.

F o r

o n l y

Task 4:

Unit 4: Bills of Material

3.

PLM114

Check your BOM for T-F## to view the results. a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Display or use transaction code CS03.

b)

Enter the material T-B##, plant 1000, usage 1, valid from date today valid to date 2 months from today, and choose Enter .

c)

Check the validity dates of the components.

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

176

© 2006 SAP AG. All rights reserved.

2006/Q2

PLM114

Lesson: Managing Bills of Material

Lesson Summary You should now be able to: • Demonstrate the validity process and changing an active bill of material • Demonstrate how engineering change management (ECM) affects the validity of a bill of material • Describe the process of archiving and deleting a bill of material

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

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177

Unit 4: Bills of Material

PLM114

Lesson: BOM Reporting Lesson Overview This lesson covers BOM explosion, where-used list and BOM comparison.

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

Demonstrate the various bill of material reports that are available to individuals Demonstrate the comparative reporting tools for bills of material

o n l y

C S C

b y

Detailed BOM Reporting

b y

i n t e r n a l

u s e

u s e

The BOM explosion answers the question, what a product consists of.

i n t e r n a l

As an engineer/planner who is responsible for maintaining bills of material, you constantly review and compare bills of material. To support others in this role, you must be aware of the reports available to review and compare individual bills of materials, as well as multilevel bills of material.

F o r

Business Example

C S C

F o r

o n l y

Figure 77: BOM Explosion

178

© 2006 SAP AG. All rights reserved.

2006/Q2

PLM114

Lesson: BOM Reporting

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.

F o r

o n l y

• • • •

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

o n l y

F o r

C S C

Figure 78: Where-Used Lists

You can create where-used lists for: • • • • • •

2006/Q2

Work centers Capacities Production resources/tools Reference operation sets Materials Documents

© 2006 SAP AG. All rights reserved.

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Unit 4: Bills of Material

PLM114

You can use the object overview to select the list you require.

b y

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.

o n l y

u s e

i n t e r n a l

Comparing Bills of Material

F o r

The BOM comparison is useful if: • • •

180

Several BOMs exist for a material. BOMs have different uses. BOMs have different change statuses.

© 2006 SAP AG. All rights reserved.

C S C

•

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

b y

• • •

u s e

Examples of situations where this information is required:

i n t e r n a l

C S C

o n l y

F o r

Figure 79: Single-Level and Multilevel Material Where-Used Lists

2006/Q2

Figure 80: BOM Comparison

You can select which fields you want to compare.

F o r

o n l y

Lesson: BOM Reporting

C S C

PLM114

The comparison can be single-level or multilevel.

b y

i n t e r n a l

u s e

u s e

b y

i n t e r n a l

C S C

F o r

o n l y

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181

Unit 4: Bills of Material

PLM114

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

182

© 2006 SAP AG. All rights reserved.

2006/Q2

PLM114

Lesson: BOM Reporting

Exercise 7: Multilevel BOM Reporting Exercise Objectives After completing this exercise, you will be able to: • Evaluate BOM explosion reports • Execute a where-used report for a component item • Compare two bills of material

Business Example

o n l y

Task 1:

i n t e r n a l

Execute a level-by-level BOM report for material T-F##.

2.

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

3.

Which items are non-stock items?

4.

Which item is handled as bulk material?

b y

i n t e r n a l

u s e

u s e

b y

C S C

Execute and navigate various BOM reports. 1.

F o r

You are responsible for managing BOMs. As part of the process, evaluations are required to understand where components are used and compare bills of material for similar products.

C S C

F o r

o n l y

Continued on next page

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Unit 4: Bills of Material

PLM114

5.

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

6.

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

o n l y

F o r

C S C

BOM Comparison. Compare your BOM T-F## in plant 1000 with the group BOM for T-F## single-level and summarized.

b y

i n t e r n a l

u s e

u s e

b y

1.

i n t e r n a l

Task 2:

C S C

F o r

o n l y

184

© 2006 SAP AG. All rights reserved.

2006/Q2

PLM114

Lesson: BOM Reporting

Solution 7: Multilevel BOM Reporting Task 1: Execute and navigate various BOM reports. 1.

Execute a level-by-level BOM report for material T-F##. a)

Choose Logistics → Production → Master Data → Bills of Material → Reporting → BOM Explosion → Material BOM → BOM Level by Level.

b)

Enter the Material: T-F##(Default) Plant: 1000 (Default)

o n l y

c)

C S C

Which items in multilevel BOM T-F## (plant 1000) have spare part indicator A? Answer: Green arrow by Level: Initial screen.

b y

or press F8.

back (or press F3) to the Explode BOM: Level

u s e

u s e

Select View . Enter A (Spare part customer A) in the Spare Part ID. field. (To see ALL spare parts, enter X in the Spare part sel. field.)

Which items are non-stock items?

F o r

Choose Execute

.

Continued on next page

2006/Q2

© 2006 SAP AG. All rights reserved.

185

o n l y

back (or press F3) to the Explode BOM: Level Answer: Green arrow by Level: View screen. Delete the spare part entry. Enter Item category N (non-stock item).

C S C

i n t e r n a l

b y

. Choose Execute Fly wheel: 100-200 3.

i n t e r n a l

2.

Access the report via Execute

F o r

Application: PP01 (Production – general)

Unit 4: Bills of Material

4.

PLM114

Which item is handled as bulk material? Answer: Green arrow back (or press F3) to the Explode BOM: Level by Level: View screen. Delete the non-stock entry. Select the box next to Bulk Material. Choose Execute . Hexagon head screw M10: 100-130.

5.

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

o n l y

C S C

b y

u s e

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

i n t e r n a l

F o r

o n l y

Continued on next page

186

© 2006 SAP AG. All rights reserved.

C S C

. Select next screen Enter Required qty: 1 and Plant: 1000. Choose Execute.

b y

Answer: Choose Logistics → Production → Master Data → Bills of Material → Reporting → Where-Used List → Material. Enter the following: Material: 100-130 Type of where-used list: Direct

u s e

6.

i n t e r n a l

. Choose Execute The answer may vary: approximately 110, including totals indicator.

F o r

Answer: Choose Logistics → Production → Master Data → Bills of Material → Reporting → BOM Explosion → Material BOM → Summarized BOM. Enter the following: Material: T-F## Plant: 1000 Application: PP01 Required quantity: 10

2006/Q2

PLM114

Lesson: BOM Reporting

Task 2: BOM Comparison. 1.

Compare your BOM T-F## in plant 1000 with the group BOM for T-F## single-level and summarized. a)

ChooseLogistics → Production → Master Data → Bills of Material → Reporting → BOM Comparison.

b)

Enter the following in the Primary BOM area: Material: T-F## Plant: Usage: 1

o n l y

c)

F o r

Change Number: Enter the following in the Secondary BOM area:

C S C

Plant: 1000

b y

Change Number:

i n t e r n a l

Material: T-F## Usage: 1

u s e

Choose Summarized Comparison

.

u s e

d) e)

i n t e r n a l

display the

icon.

C S C

3.

icon. Components with equal quantities are represented by the Same component but with different quantities are represented by the icon. Components that are required on one BOM but not the other

b y

1. 2.

F o r

o n l y

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187

Unit 4: Bills of Material

PLM114

Lesson Summary You should now be able to: • Demonstrate the various bill of material reports that are available to individuals • Demonstrate the comparative reporting tools for bills of material

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

188

© 2006 SAP AG. All rights reserved.

2006/Q2

PLM114

Lesson: Configuration of the Bill of Material

Lesson: Configuration of the Bill of Material Lesson Overview This lesson discusses the detailed configuration of the bill of material.

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

Describe the configuration activities surrounding the BOM header Describe the configuration activities surrounding the BOM items

o n l y

C S C

b y

u s e

You can do the following by making the corresponding settings in the modification parameters:

F o r

The technical types multiple BOM and variant BOM can be deactivated. In other words, no maintenance of bills of technical BOM types M and V is possible. In BOM items, you can use the explosion type of a BOM item to display by validity and define which text is displayed for a variable-size item.

2006/Q2

© 2006 SAP AG. All rights reserved.

189

o n l y

In the group box for validity, engineering change management (history requirement) for bills of material is defined. The low date setting means that the BOM validity is set to the earliest processing date when it is created by the system, that is, 01.01.1900. The low date cannot be changed. The valid-from date is a default value and can be changed by the user. If the low date is not activated (checkbox blank), the system proposes today's date as the valid-from date.

C S C

i n t e r n a l

Control the validity of a bill of material Allow or disallow technical types for bills of material Maintain the settings for items Make general BOM settings

b y

• • • •

u s e

The BOM Header: Defining Modification Parameters

i n t e r n a l

As the project lead for implementing bills of material, you must be aware of the structural design of the object in SAP ECC. In doing so, you will learn how the bill of material is structured to integrate with several business areas in your company. Your company has requirements to use bills of material for costing, engineering and production. To support these integrated functions, you must be aware of what configuration options are available to your company.

F o r

Business Example

Unit 4: Bills of Material

PLM114

In the general settings, the base unit of measure is defined for BOM headers of special BOM categories, such as equipment BOM and document structure, and for special item categories. In addition, you can activate the CAD interface for bills of material (material BOMs only).

BOM Default Settings Default values for the BOM header and settings for variable-size items are defined in Customizing: Base quantity for bill of material BOM status Unit of measure for size and number of variable-size items

The following default values can be defined by the user or preset in Customizing:

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Item increment Item category Material provision indicator Various BOM reporting options

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You can use default values to organize data entry effectively.

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The abbreviations in the graphic have the following meanings:

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Configuration Sequence BOMs, BOM Status, BOM Item Status M = Mandatory activity (must)

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O = Optional activity (optional) D = Default available for activity (default)

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Each user can also define their own default values to optimize or simplify data entry. However, this requires specific authorization. Alternatively, these settings can be defined for a user in Customizing.

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• • • •

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Lesson: Configuration of the Bill of Material

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Hint: When defining the BOM usage, the next step must be checking and maintaining the settings for default values for item status.

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The user-specific settings can be defined in Customizing for each user – with a high administrative overhead – or each user maintains their own user-specific settings in the master data functions for bills of material.

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The object types for BOM items may not be changed.

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At BOM header level, the department or person responsible and the history requirement for bills of material can be defined. When you process a bill of material with history requirement activated an additional authorization object is checked (C_STUE_NOH). If this authorization is assigned to a user, the user can change bills of material that have a history requirement without a change master record.

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Figure 81: Sequence for Customizing Bills of Material

Unit 4: Bills of Material

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C S C

Hint: When defining the BOM usage, the next step must be checking and maintaining the settings for default values for item status.

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When you configure your system in Customizing (Bill of Material → BOM usage → Define BOM usages), you define which item statuses are allowed or disallowed for each BOM usage (general setting is valid for all items). Fine-tuned control is defined for each individual item. You can define item status fields as required, optional, or disallowed for a specific application area in your company.

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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.

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Figure 82: BOM Status and BOM Item Status

PLM114

Lesson: Configuration of the Bill of Material

Alternative Determination

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F o r

Variable-Size Item/ Item Category “R” Variable-Size Item with Formula for a Cylinder Enter this item category to represent parts of a material of different sizes under one material number. On the detail screen: After entry, the system calculates variable-size quantity of the material consumed by the component usage.

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In addition, you can specify a selection ID that decides the sequence in which the system searches for bills of material if several bills of material have been created for one material with different usages. For this purpose, a selection ID with a selection priority is maintained for each BOM usage. The selection priority is entered as a number, whereby the lowest number has the highest priority.

C S C

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BOM explosion in general Inventory management Engineering Production Costing Maintenance and so on.

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• • • • • •

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Alternative selection for cases where several alternative BOMs exist can be controlled dependent on material/plant/usage and an alternative with validity date. It can also be controlled by other applications, such as the following:

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Figure 83: Alternative Determination

Unit 4: Bills of Material

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Figure 84: Variable-Size Item with Formula for a Cylinder

Advantages:

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•

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MRP can be executed by exploding the BOM without any additional work steps. You do not have to create a separate material master for each size.

Entering a formula for variable-size item calculation also enables complex calculations.

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Size 1 for lengths Size 1 * Size 2 for areas Size 1 * Size 2 * Size 3 for volumes

© 2006 SAP AG. All rights reserved.

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• • •

C S C

If no formula key is entered, the following formula is used:

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Caution: You can only use the variables ROMS1 – ROMS3, the constant pi, and the operators +, -, *, and /.

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In Customizing for item data, you can define your own formulas and assign them when creating new variable-size items.

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•

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Lesson: Configuration of the Bill of Material

Item Categories The following item categories are defined in the standard system: • • • • • • • •

Stock item Non-stock item Variable-size item Text item Document item PM structure element Class item Intramaterial (PP-PI)

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Figure 85: Item Categories

The item category controls:

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Whether a material must, can, or cannot be entered Whether quantities can be negative or positive or both Whether quantities can be negative or positive or both Whether subitems are allowed Which item detail screens (ItmCtrl) are required for specific item categories. Example: A variable-size item requires variable-size item data.

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• • • • •

Unit 4: Bills of Material

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PLM114

Lesson: Configuration of the Bill of Material

Exercise 8: Bill of Material Configuration Exercise Objectives After completing this exercise, you will be able to: • Set the status, application and use of a BOM • Set up default values for a user

Business Example You must adapt the BOM management of your SAP ECC to suit the requirements of your company and users.

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1.

Effectivity (validity): Low date

2.

Technical type: Mult. BOM inactive

Set the default settings for your user so that the item increment is 8. Item category L is the default setting when you create a material item and category D when you create a document item.

2.

Test the user-specific settings by changing your material BOM T-F## in plant 1000 with usage 1.

Task 3:

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Define BOM usage. 1.

With usage Universal, which fields are required fields?

Task 4: In which order of priority are bills of material (BOM usages) selected according to the selection ID stored for BOM application PP01 (production general)?

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1.

Which selection ID does the BOM application PP01 use?

2.

What is the order of priority of BOM usages?

© 2006 SAP AG. All rights reserved.

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1.

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You need to maintain user-specific default values for your user.

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Task 2:

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When configuring bills of material by defining modification parameters, what is the effect if you change the modification parameters for BOMs by selecting the following checkboxes?

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Task 1:

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Unit 4: Bills of Material

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Solution 8: Bill of Material Configuration Task 1: When configuring bills of material by defining modification parameters, what is the effect if you change the modification parameters for BOMs by selecting the following checkboxes? 1.

Effectivity (validity): Low date a)

In Customizing choose Production → Basic data → Bill of material → Control data for bills of material→ Define modification parameters. Select validity. low date checkbox and press F1 (help).

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2.

Technical type: Mult. BOM inactive

C S C

In Customizing choose Production → Basic data → Bill of material → Control data for bills of material→ Define modification parameters.

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Select technical type: multiple BOM inactive checkbox and press F1 (help).

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No multiple BOMs can be maintained in ECC; in other words, you cannot maintain alternatives for an existing bill of material.

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a)

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When BOMs are created or edited, the default date is the earliest processing date defined in the system: 01.01.1900.

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Continued on next page

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Lesson: Configuration of the Bill of Material

Task 2: You need to maintain user-specific default values for your user. 1.

Set the default settings for your user so that the item increment is 8. Item category L is the default setting when you create a material item and category D when you create a document item. a)

Set up the default values for a user in Customizing: choose Production → Basic data → Bill of material → Define user-specific settings.

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C S C

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Highlight the settings for an existing user. Click Copy As

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Replace existing user with your user ID. Test the user-specific settings by changing your material BOM T-F## in plant 1000 with usage 1. Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change.

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Task 3: Define BOM usage. 1.

With usage Universal, which fields are required fields? a)

In Customizing, choose Production → Basic data → Bill of material → General data → BOM usage → Define BOM usage. When universal is used, no field is set as mandatory because all fields with „ , „ are optional entries, except PM relevancy, which cannot be entered. Continued on next page

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Results: Item increments for all subsequent new items are set at intervals of 8. For material items, item category L is proposed; for document items, item category D is proposed.

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Change the BOM T-F2##.

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a)

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Choose Enter . Make the appropriate changes and choose Save. 2.

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Caution: The same settings can be maintained by the user in the application for creating or changing a bill of material, provided that the user has the authorization for this. On the Change/Display Material BOM initial screen, choose Settings → Current settings. You can also get to the default values from the SAP Easy Access screen: choose Production → Master data → Bills of material → Environment → Current settings → User-specific settings (transaction OS29).

Unit 4: Bills of Material

PLM114

Task 4: In which order of priority are bills of material (BOM usages) selected according to the selection ID stored for BOM application PP01 (production general)? 1.

Which selection ID does the BOM application PP01 use? a)

In Customizing, choose Production → Basic data → Bill of material → Alternative determination → Define applications. Results: PP01 uses selection ID 01.

2.

What is the order of priority of BOM usages? a)

In Customizing, choose Production → Basic data → Bill of material → Alternative determination → Define order of priority for BOM usages.

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The order of priority of the SelID (selection ID) is: 1 (Production) 3 (Universal)

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Example: If a material has several bills of material with different usages (one internal BOM number for each usage), the system searches for a production BOM first, then for a universal BOM, and then for an engineering/design BOM.

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2 (Engineering/design)

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PLM114

Lesson: Configuration of the Bill of Material

Lesson Summary You should now be able to: • Describe the configuration activities surrounding the BOM header • Describe the configuration activities surrounding the BOM items

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Unit Summary

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Unit Summary

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You should now be able to: • Describe the organizational layout of the bill of material • Demonstrate the validity process and changing an active bill of material • Demonstrate how engineering change management (ECM) affects the validity of a bill of material • Describe the process of archiving and deleting a bill of material • Demonstrate the various bill of material reports that are available to individuals • Demonstrate the comparative reporting tools for bills of material • Describe the configuration activities surrounding the BOM header • Describe the configuration activities surrounding the BOM items

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PLM114

Test Your Knowledge

Test Your Knowledge 1.

A bill of material is a complete, formally structured list of components that make up a product or assembly. Determine whether this statement is true or false.

□ □ 2.

True False

All of the components are stored in a multilevel bill of material for the finished goods. Determine whether this statement is true or false.

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C S C

A material BOM is the only BOM category that can be created in the SAP ECC system. Determine whether this statement is true or false.

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A material BOM can have many different usages for specific departments within a company. Determine whether this statement is true or false.

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Each material BOM is material and plant unique and each material plant combination BOM has a separate internal number assigned to it.

F o r

□ □ 6.

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Determine whether this statement is true or false.

True False

At minimum a basic data view of a material master record must exist before you can create a BOM for that material. Determine whether this statement is true or false.

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True False

© 2006 SAP AG. All rights reserved.

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5.

True False

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4.

True False

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3.

True False

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7.

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The base unit of measure defaults into the BOM item but can be overridden with the issue unit of measure from the work scheduling view if it is populated. Determine whether this statement is true or false.

□ □ 8.

True False

Each time a BOM is saved the system calculates the low level code which is used for planning. Determine whether this statement is true or false.

9.

True False

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□ □

The area of validity is: Choose the correct answer(s).

C S C

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A B C D

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□ □ □ □

The materials that can use a BOM The plants that can use a BOM The materials that are used by a BOM as components The industry that can use a BOM

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Choose the correct answer(s).

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The materials that can use a BOM The plants that can use a BOM The time during which a BOM can be used to create an order The time during which a BOM is created

11. Select each of the following that is not an item category.

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□ □ □ □ □

A B C D E

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Choose the correct answer(s).

Stock item Non-stock item Class item Non-class item Text item

12. Once an item category is assigned to a BOM item it cannot be changed. Determine whether this statement is true or false.

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True False

© 2006 SAP AG. All rights reserved.

C S C

A B C D

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10. The validity period is:

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Test Your Knowledge

13. A variable sized item category requires you to enter the dimensions of the item. Determine whether this statement is true or false.

□ □

True False

14. A non-stock item category does not require a material number. Determine whether this statement is true or false.

□ □

True False

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Determine whether this statement is true or false.

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True False

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16. Select each of the following that is a reason to use engineering change management. Choose the correct answer(s).

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Determine whether this statement is true or false.

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True False

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17. When making a change to a BOM using a change number the validity dates on the BOM are changed to match the key date in the change number.

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Monitoring and documentation of changes Planning and execution at a specific point in time You can save several change statuses for the same object. Integration in the logical process chain All of the above None of the above

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A B C D E F

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15. A recursive component on a BOM appears twice as a component with two different item numbers.

Test Your Knowledge

PLM114

18. Select each of the following that are ways to delete a BOM. Choose the correct answer(s).

□ □ □ □ □

A B C D E

Delete the entire BOM Delete a BOM item Set the deletion indicator Delete with a change number Archive the BOM

19. Which report would you use to determine which BOMs will be affected by a component change? Choose the correct answer(s).

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BOM comparison Level by level BOM explosion Multilevel BOM explosion Material where-used list

20. Which report would you use to see an overview of all the necessary parts and materials?

b y

Choose the correct answer(s).

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BOM comparison Level by level BOM explosion Multilevel BOM explosion Material where-used list

21. Which report would you use to see the differences between two BOMs with different change statuses?

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Choose the correct answer(s).

F o r

A B C D

BOM comparison Level by level BOM explosion Multilevel BOM explosion Material where-used list

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□ □ □ □

22. Which of the following are required to be configured before you can create a BOM? Choose the correct answer(s).

□ □ □ □ □

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A B C D E

BOM usage BOM status Item Categories User-specific settings None of the above

© 2006 SAP AG. All rights reserved.

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A B C D

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Test Your Knowledge

23. You can control which material types can be used as the header material when creating a BOM. Determine whether this statement is true or false.

□ □

True False

24. A material with any material type can be used as a BOM component and this cannot be changed in the system. Determine whether this statement is true or false.

True False

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□ □

25. Which of the following can be set in the user-specific settings? Choose the correct answer(s).

C S C

Item increment Default item category for materials Default BOM usage Default BOM category

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A B C D

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Answers 1.

A bill of material is a complete, formally structured list of components that make up a product or assembly. Answer: True A bill of material is a complete, formally structured list of components that make up a product or assembly.

2.

All of the components are stored in a multilevel bill of material for the finished goods.

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b y

3.

A material BOM is the only BOM category that can be created in the SAP ECC system.

4.

Answer: True

F o r

5.

Each material BOM is material and plant unique and each material plant combination BOM has a separate internal number assigned to it. Answer: False Each material BOM is unique for the material, plant, usage combination and each of those combinations had a unique internal group number.

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A material BOM can have production, engineering, costing, sales, plant maintenance usages

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A material BOM can have many different usages for specific departments within a company.

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The BOM categories that can be created in the SAP ECC system are material, order, document, equipment, and functional location BOMs.

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Answer: False

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All bills of material are stored as single-level BOMs in the system. So the BOM for the finished goods consists of its direct components, each of which may have its own single-level BOM in the system. This linkage creates a multilevel BOM and can be viewed by using BOM reporting.

F o r

Answer: False

PLM114

Test Your Knowledge

6.

At minimum a basic data view of a material master record must exist before you can create a BOM for that material. Answer: True At minimum a basic data view of the material master must exist before you can create a BOM for that material. If only the basic data view exists, only a group BOM can be created and cannot be allocated to a plant until a plant specific view exists.

7.

The base unit of measure defaults into the BOM item but can be overridden with the issue unit of measure from the work scheduling view if it is populated.

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C S C

b y

8.

Each time a BOM is saved the system calculates the low level code which is used for planning.

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The area of validity is:

b y

9.

When you create a BOM a low level code is automatically assigned to each material used in MRP and costing.

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Answer: True

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Answer: B The area of validity defines which plants can use a bill of material.

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10. The validity period is: Answer: C The validity period is the time during which the BOM is valid to create an order and is defined in the BOM header.

2006/Q2

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The system proposes the base unit of measure from the material master record as the default unit. However, if the alternative unit of measure unit of issue is maintained in the Work Scheduling view, this can be used.

F o r

Answer: True

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11. Select each of the following that is not an item category. Answer: D The BOM item categories are L stock item, N non-stock item, R variable sized item, T text item, D document item, K class item, I a PM structure element, and M phantom or intra-material. Non-class item is not an item category in the SAP ECC system. 12. Once an item category is assigned to a BOM item it cannot be changed. Answer: True

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Answer: True

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b y

When you enter an item with variable sized item category the system gives you a chance to enter 3 dimensions for the product and a formula for calculation.

Answer: True

F o r

Answer: False A BOM is recursive if the product contains a component that has the same object number as the product, i.e., when a component and the header materials have the same material number.

© 2006 SAP AG. All rights reserved.

2006/Q2

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15. A recursive component on a BOM appears twice as a component with two different item numbers.

C S C

You can create non-stock items both with or without a materials master record. If you create a non-stock item without entering a material number, you must enter a descriptive text and purchasing data.

b y

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14. A non-stock item category does not require a material number.

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13. A variable sized item category requires you to enter the dimensions of the item.

F o r

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.

PLM114

Test Your Knowledge

16. Select each of the following that is a reason to use engineering change management. Answer: E All of the above are reasons to use engineering change management. 17. When making a change to a BOM using a change number the validity dates on the BOM are changed to match the key date in the change number. Answer: True

F o r

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The date in the change number becomes the validity date for the BOM item and header. 18. Select each of the following that are ways to delete a BOM.

Answer: D

F o r

Answer: C The BOM explosion answers the questions, what a product consists of. To get an overview of the entire structure of all necessary parts and materials a multilevel BOM explosion report is available.

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20. Which report would you use to see an overview of all the necessary parts and materials?

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The where-used list provides an answer to the questions, where a material is used and in what quantity. It can be used to find the products that are affected by a change to an individual part.

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19. Which report would you use to determine which BOMs will be affected by a component change?

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b y

C S C

You can delete a BOM using the deletion function or the deletion indicator. You can delete the entire BOM or delete individual items. BOMs can be deleted without history or with history using engineering change management. Archiving a BOM is saving a copy of it when you remove it from the database.

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Answer: A, B, C, D

Test Your Knowledge

PLM114

21. Which report would you use to see the differences between two BOMs with different change statuses? Answer: A The BOM comparison is useful if two BOMs have different change statuses. The comparison can be either single-level or multilevel. 22. Which of the following are required to be configured before you can create a BOM? Answer: E

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Answer: True

b y

In Materials types for use in BOMs, you can indicate which material types can be used as the header material in a BOM.

u s e

In material types for BOM items, you can control which material types can be entered as components on the BOM.

C S C

25. Which of the following can be set in the user-specific settings?

F o r

The item increment and the default item category for materials as well as several other settings can be set in the user-specific settings. It is not possible to default the BOM usage and BOM category in the user-specific settings since these are picked by the transaction or the entry screen prior to BOM maintenance.

© 2006 SAP AG. All rights reserved.

2006/Q2

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Answer: A, B

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Answer: False

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24. A material with any material type can be used as a BOM component and this cannot be changed in the system.

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23. You can control which material types can be used as the header material when creating a BOM.

F o r

Since all of the above can use the default settings delivered with your SAP ECC system or are optional configuration activities, none of them is required.

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Unit 5 Modeling the Manufacturing Process Unit Overview

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After completing this unit, you will be able to:

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Lesson: Modeling Manufacturing .............................................215 Lesson: Basic Work Center Data and Defaults .............................221 Exercise 9: Create a Work Center .......................................229 Lesson: Capacities in the Work Center ......................................238 Exercise 10: Capacities in the Work Center ............................241 Lesson: Integrating Costing with the Work Center .........................250

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Unit Contents

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Describe the purpose and integration points of the task list (routing) Describe the structure and purpose of the work center Describe the purpose of the standard value key and standard values Describe the purpose of defaults in the work center Create standard texts to describe a process step Describe capacities and demonstrate their maintenance Describe the function of a pooled work center Describe a reference work center Use reference and pooled capacities Describe the how the work center integrates with costing Demonstrate how the work center and the task list interact with the cost center Define default values for work centers Explain the configuration settings regarding work centers Create and test work center formulas

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Unit Objectives

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This unit introduces the concept of the SAP ERP work center and how it is used in the task list. You will be instructed on the creation, maintenance, and configuration of the work center. You will also execute various transactions to manage the process surrounding its life cycle.

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Lesson: Configuring the Work Center .......................................253 Exercise 11: Optional: Work Center Formulas .........................265 Exercise 12: Work Center Category and Field Selection Control, Default Work Center (Optional) ...........................................271

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Lesson: Modeling Manufacturing

Lesson: Modeling Manufacturing Lesson Overview This lesson provides a basic definition and introduction to SAP ERP work centers and task lists (routings).

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

Describe the purpose and integration points of the task list (routing) Describe the structure and purpose of the work center

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In manufacturing, everything revolves around master data, which determines the relationships between the materials used in production and the production process. Material masters must exist before a bill of material and its components can be created.

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Introduction to Modeling Manufacturing

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As the project lead for implementing manufacturing resources, you must be aware of the structural design of the work center object in SAP ERP. You need to learn how the task list and work center are structured to integrate with several business areas in your company. Your company has requirements to use task list and work centers for costing, engineering, and production.

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Business Example

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Bills of materials indicate what materials are used to produce a product. The components in a BOM can be assigned to specific operations where they are required.

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Standard SAP R/3 texts can be created and assigned to PP basic data objects. The SAP R/3 classification system can be used to group PP basic data according to user-defined attributes. For the material you want to produce, you must set the procurement type to in-house production (X,E). You must maintain at least one plant-specific view (MRP and/or work scheduling) in the accounting and costing views for the material.

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Documents created in document management can be assigned as components in BOMs, or as a production resource tool (PRT) to routing operations.

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Production resources and tools identify the tools needed to do the work. They can be assigned to operations.

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Routings are more complex and pull the other pieces of master data together. Routings define the operational steps required to produce the item, along with the time required, work center where the work is done, and other manufacturing control data.

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Work centers must be defined before they can be used in an operation.

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Figure 86: Data: Modeling Manufacturing

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Lesson: Modeling Manufacturing

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A work center is a location that defines where production activities take place according to order requirements. In different companies, work centers are also called machine centers or capacity centers.

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Work centers can be defined as individual or multiple machines, people, tools, and so on. Work centers are used in routings (routings, standard networks, inspection plans, maintenance task lists, and rough-cut planning profiles) and in orders. Work centers can also be used to collect capacity for statistical evaluations.

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Figure 87: Work Center

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Figure 88: Work Center Integration

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Work centers are integrated with and support a number of areas, most commonly scheduling, capacity planning, and costing.

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Where the work is to be done How long the work should take What materials are needed for each operation What tools and fixtures are required

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A routing shows operations in a sequence and acts as a template for production orders. The planned time for each operation is stored in the routing as standard values. These standard values are the basis for:

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Figure 89: Routing

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Figure 90: Routing Usage

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Lead time scheduling Product costing Capacity planning

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Routings are critical to a number of functional activities within SAP ERP. These form the basis for:

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Lesson Summary You should now be able to: • Describe the purpose and integration points of the task list (routing) • Describe the structure and purpose of the work center

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Lesson: Basic Work Center Data and Defaults

Lesson: Basic Work Center Data and Defaults Lesson Overview In this lesson you will learn what data is contained in a work center, what is required, and how the data is used. You will also learn how to create a new work center.

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

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Describe the purpose of the standard value key and standard values Describe the purpose of defaults in the work center Create standard texts to describe a process step Describe capacities and demonstrate their maintenance

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Similar to the material master, the work center is made up of several subscreens. Work centers are plant-specific and can be used in routings. However, for production orders, it is mandatory to assign cost centers and activity types.

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Work Center Data

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As the engineer/planner responsible for maintaining work centers, you must be aware of the structural design of the objects in SAP ERP. Work centers will only be created periodically after the initial go live of your implementation. In doing so, you need learn how the basic data and defaults will affect the modeling of your manufacturing process in the task list. You will also have to maintain the capacity and scheduling related data for work centers to integrate them properly.

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Business Example

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Default values that are copied or referenced in operations when you create routings Costing data that enables the costing of operations Scheduling and capacity data required for lead time scheduling and capacity planning

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Work centers determine the place where the operation is to be executed. They contain:

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Figure 91: Work Center

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Figure 92: Work Center Data

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Lesson: Basic Work Center Data and Defaults

A work center contains several groups of data that you can enter on various screens (tab pages). Default values are copied to the routing. You use the reference indicator to specify whether a default value can be changed in the routing.

Standard Value Key Standard values represent the times to be measured when the work center is used on a task list, for example, machine time, labor time, and setup time.

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Default Values The work center contains default values that are copied when you create an operation and that can be changed in the operation, if necessary. However, if the default values are marked as a reference in the work center, then you cannot make a change in the operation. The default values for work center maintenance are stored in Customizing per plant for the order type.

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The standard value key is entered on the work center Basic data tab. The key can be set to required or optional within the work center.

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These times are grouped together using a standard value key. This key determines which standard values are displayed for the work center.

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Figure 93: Standard Value Key

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Note: When setting up an SAP R/3 PP system, you should make sure that as much data as possible is defined in work center maintenance.

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The default values are copied to routings or production orders. This data is saved partly in various screens in the work center. Activity types are proposed from the cost center assignment screen.

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Figure 94: Default Values in Work Centers

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Figure 95: Standard Text for Operation Description

Standard texts for operation descriptions can be predefined in SAP R/3. To maintain standard texts, choose Routings → Extras → Standard text.

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A standard text key identifies the standard text. You can specify this key in the work center. When you use the work center in a routing, the standard text is copied or referenced in the operation.

Work Center Capacity A major function of work centers is to support capacity planning and scheduling. In order to plan these functions, the available capacity must be maintained in the work center.

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Work center capacities Pooled capacities Reference capacities Default capacities

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Capacity refers to the ability of a work center to perform a specific task. You distinguish between various capacities in a work center, such as labor or machines, by using the capacity category. To plan capacities in more detail, you can define individual capacities for each capacity, for instance in the capacity category Person 3 employees or in the capacity category machine 5 lathes. Capacities can be entered and changed in work centers, but can also be maintained independently. The system distinguishes between:

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Figure 96: Capacity Categories for a Work Center in SAP ERP

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Capacity planning: The available capacity and formulas for calculating capacity requirements are entered in the work center.

Work Center Scheduling Parameters

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Shift sequences and shift definitions can be created and selected for special areas in Customizing with the help of the grouping key.

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Shift sequences and shift definitions can be used for detailed maintenance of the available capacity for each capacity category only if you use intervals.

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Scheduling: Operating times and formulas are entered in the work center, so that the duration of an operation can be calculated.

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Each work center can have one or more capacity headers to describe any limit to the work it can perform in regards to time. For capacity headers to function, they must be assigned as time to a work center. The capacity header will contain all the necessary information to identify the available capacity for a constraint.

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Figure 97: Capacity Header

Lesson: Basic Work Center Data and Defaults

Figure 98: Available Capacity Maintenance Using Central Shift Sequences

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You define the work start, work finish, and break times for all work centers in a shift definition. In shift sequences, you maintain the sequence of individual shift definitions for all shift sequences.

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Figure 99: Scheduling Data at a Work Center

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The move time can be maintained separately. You can maintain a minimum move time and a normal move time in the Interoperation times section of the Operation detail screen. If reduction measures are necessary, the system uses the minimum move time for scheduling. Note: The system uses the move time matrix to determine move times only if you have not entered any move times in the Interoperation times section of the Operation detail screen. As a rule, however, the transport time should be determined by means of the location groups from the sequential work centers and the move time matrix in Customizing.

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You can maintain the queue time in the work center and in the routing operation. However, the system uses the queue time from the work center for scheduling only if you have not maintained a queue time in the operation. If reduction measures are necessary, the value is reduced from the normal queue time to the minimum queue time.

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In the move time matrix, you can maintain the planned move times within a location group or between two location groups and several plants.

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You can group work centers that are close together in a location group. You maintain location groups in Customizing. In the scheduling data screen for the work center, you assign the work center to a location group.

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Lesson: Basic Work Center Data and Defaults

Exercise 9: Create a Work Center Exercise Objectives After completing this exercise, you will be able to: • Create and change a work center

Business Example Two new machines have been purchased to support the assembly process for the new pump. You are responsible for the definition of a new work center that represents the two new machines.

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Create work center CENTER## in plant 1000. The work center is intended for two identical new machines with the work center category 0003.

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Create work center CENTER## in plant 1000.

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Hint: To maintain the individual tab pages (screen sequences), select Next screen.

Entry

Description

Pump assembly ##

Person responsible

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Usage

009 (All task list types)

Standard value key

SAP1 (Normal production)

Rules for maintenance

Setup time - should be entered

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Field

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Enter the following on the Basic data tab page:

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Machine time - must be entered Labor time - is not checked Performance efficiency rate key

Machine - 090 %

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Task 1:

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On the Default values tab page, choose the control key (between PP01 and PP99) and minutes as the unit of measure. Set the reference indicator for the control key. Note: Choose a control key from the PP series (PP01 to PP99). It must allow scheduling, capacity planning, and costing. It must also print time tickets and allow confirmations.

Task 2: Answer the following questions about the work center that you have just saved. Can you define operations using this work center without entering a setup time?

2.

Can you use a work center in which only the Basic data and Default Values tab pages have been defined in routing operations?

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Task 3: Add data for capacity, scheduling, and costing to the work center CENTER##. To do so, use the change transaction.

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Enter the capacity category 001, Setup Formula SAP005, Processing Formula SAP006. On theChange Work Center Capacity: Header screen, adjust the capacity data using the following capacity data: Field

Entry

Capacity planner group

0##

Grouping

51

Factory Calendar ID

01

Active Version

1

Base unit of measure

Hour Continued on next page

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Field

Entry

Start/finish time

08:00 / 17:00

Length of breaks

1 hour

Capacity utilization

80 %

Number of individual capacities 2 machines

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Entry

Scheduling basis: Capacity category

001

Setup formula

SAP001

Processing formula

SAP002

Location group

0002

Standard queue time

2 hours

Maintain the following data on the Costing tab page: Field

Entry

Cost center

4230

Activity type

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Maintain the Scheduling tab page with the following data:

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Setup time -1422

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Machine time -1420

Setup - SAP005

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Machine - SAP006

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Solution 9: Create a Work Center Task 1: Create work center CENTER## in plant 1000. The work center is intended for two identical new machines with the work center category 0003. 1.

Create work center CENTER## in plant 1000.

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Enter plant 1000, work center number CENTER##, and work center category 0003.

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Choose Enter .

Enter the following on the Basic data tab page: Entry

Description

Pump assembly ##

Person responsible

0##

Usage

009 (All task list types)

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Choose Logistics → Production → Master Data → Work Centers → Work Center → Create.

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Hint: To maintain the individual tab pages (screen sequences), select Next screen.

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Field

Entry

Standard value key

SAP1 (Normal production)

Rules for maintenance

Setup time - should be entered Machine time - must be entered Labor time - is not checked

Caution: Do not save or exit the work center at this time. On the Default values tab page, choose the control key (between PP01 and PP99) and minutes as the unit of measure. Set the reference indicator for the control key.

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Select Next screen or choose the Default Values tab.

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Maintain the following data on the Default values tab page:

c)

Field

Entry

Control key

PP01 to PP99

Unit of measure for standard values

Minute

Reference indicator

Set for the control key

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Save the work center by choosing . Continued on next page

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Note: Choose a control key from the PP series (PP01 to PP99). It must allow scheduling, capacity planning, and costing. It must also print time tickets and allow confirmations.

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Hint: After the work center number, enter the work center description, Pump assembly ##. Use the input help to enter the person responsible, usage, and standard value key.

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Maintain data from the above table. Confirm entries with Enter.

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Machine - 090 %

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Performance efficiency rate key

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Task 2: Answer the following questions about the work center that you have just saved. 1.

Can you define operations using this work center without entering a setup time? Answer: Yes, but a warning message appears that prompts you to enter a setup time.

2.

Can you use a work center in which only the Basic data and Default Values tab pages have been defined in routing operations? Answer: In the routing, yes. In the production order, no.

Add data for capacity, scheduling, and costing to the work center CENTER##. To do so, use the change transaction.

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Field

Entry

Capacity planner group

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Grouping

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Factory Calendar ID

01

Active Version

1

Base unit of measure

Hour

Start/finish time

08:00 / 17:00

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Enter the capacity category 001, Setup Formula SAP005, Processing Formula SAP006. On theChange Work Center Capacity: Header screen, adjust the capacity data using the following capacity data:

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Field

Entry

Length of breaks

1 hour

Capacity utilization

80 %

Number of individual capacities 2 machines a)

Choose Logistics → Production → Master Data → Work Centers → Work Center → Change.

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Enter Capacity category 001 , Setup Formula SAP005, and Processing Formula SAP006.

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To access the capacity header data, double-click the number of the capacity category or choose the Capacity header data button.

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Enter data from the above table and choose Enter

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Arrow back screen.

Entry

Scheduling basis: Capacity category

001

Setup formula

SAP001

Processing formula

SAP002

Location group

0002

Standard queue time

2 hours

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Enter data from the above table and confirm with Enter .

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to the Change work center: Capacity Overview

Maintain the Scheduling tab page with the following data:

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Maintain the following data on the Costing tab page:

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and select the Capacities tab.

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Choose Enter

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Field

Entry

Cost center

4230

Activity type

Setup time -1422 Machine time -1420

Formula keys

Setup - SAP005

a)

Select the Costing tab.

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Make the required entries from the table above.

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Save your work center by choosing

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Machine - SAP006

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Lesson: Basic Work Center Data and Defaults

Lesson Summary You should now be able to: • Describe the purpose of the standard value key and standard values • Describe the purpose of defaults in the work center • Create standard texts to describe a process step • Describe capacities and demonstrate their maintenance

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Lesson: Capacities in the Work Center Lesson Overview In this lesson, we will discuss pooled and reference capacities.

Lesson Objectives After completing this lesson, you will be able to: Describe the function of a pooled work center Describe a reference work center Use reference and pooled capacities

Business Example

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Many work centers also operate the same hours. To make maintaining these working hours more efficient, you want to use a reference capacity.

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Capacity refers to the ability of a work center to perform a specific task. Capacities are differentiated according to capacity category. They are arranged hierarchically under a work center. Capacity can be specific to a given work center, it can represent a group of people or machines, or it can be used as master data for many work centers.

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Pooled Capacities

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As the production planner, you are responsible for maintaining capacity and scheduling-related data for the modeling of the manufacturing process. There is currently a labor pool that is shared among many work centers. This will be modeled as a pooled capacity.

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Lesson: Capacities in the Work Center

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Often times in repetitive, high-speed, manufacturing environments, companies divide similar manufacturing activities into manufacturing areas, or departments. Often times, these departments operate at the same starting and finishing times. To properly schedule any logistics activities, users must create and maintain the necessary capacity data. However, if the data that is used to model certain resources is identical, than methods to ease data maintenance should be used.

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Reference Capacities

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In SAP R/3, capacity headers can be modeled independently of work centers to support a shared/pooled resource. In the definition of the work center, the pooled capacity will be referenced by the work center to act as a planning constraint during capacity planning.

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A pooled capacity is used to model manufacturing resources that will be shared by many work centers. For modeling purposes, this only makes sense if the pool of resources is actually a capacity constraint. Example, you have five production lines that each require an operator for the entire duration that machine runs. However, you only have four operators in you resource pool. Therefore, only four machines can run at any one time.

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In SAP R/3, capacity data can be a stand-alone piece of master data called a capacity header. Each work center can have one or more capacity headers to describe any limit to the work it can perform in regards to time. For capacity headers to function, they must be assigned at some time to a work center. In SAP R/3, capacities are created without reference to a work center when modeling a reference capacity or a pooled capacity.

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Figure 100: Pooled Capacities

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Once the work center capacity category has been referenced, it can no longer be maintained. The capacity data can only be maintained by editing the reference capacity header.

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Once a capacity header has been created, users must reference it to the same capacity category in the work centers. In the details of the capacity header, choose Extras → Reference avail. cap. This must be [performed on every work center that will use the capacity header as reference data.

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The first step in creating a reference resource is to create the capacity header. The capacity header for the reference capacity is no different then a work center capacity header. Unlike the pooled capacity, there is no field to indicate that it has a special function.

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To ensure proper scheduling, each work center in SAP R/3 is typically maintained with its available capacity so that you know when the work center is open and closed for business. By creating reference capacities, users can maintain one set of capacities that applies to several work centers independently by linking the capacity data to each relevant work center. When it is necessary to update the capacity, the planner only needs to maintain the reference resource. The information is relevant for all resources that have been linked by the reference function.

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Figure 101: Reference Capacity

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Lesson: Capacities in the Work Center

Exercise 10: Capacities in the Work Center Exercise Objectives After completing this exercise, you will be able to: • Create pooled capacities • Create a reference capacity • Assign the pool and reference to a work center

Business Example

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Task 1: Create Reference Resource

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Your assembly lines run from 7:30am to 3:30pm. Each line is available 95% of the time, due to preventive maintenance. Create a reference capacity to model this. Create a machine capacity, REF - ##, Assembly Lines, that will reflect the master data above, and model you high-speed filling line master data.

You are staffed with six operators to run the assembly lines. Model these as a pooled capacity.

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Task 2: Pooled Capacity in mySAP SCM

Create a pooled capacity, Pool - ##, that will represent the labor force that is responsible for running the assembly lines in plant 1000, based on the figures above.

F o r

Create work center Assy-## in plant 1000. The work center will use the reference capacity REF-## and pooled capacity Pool-##. 1.

Create work center Assy-## in plant 1000.

2.

Enter the following data on the Basic data tab page:

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u s e

1.

i n t e r n a l

C S C

The assembly machines are run by a pool of six people who move from machine to machine to assure things are running smoothly.

F o r

As a general rule, all assembly areas will work the same hours: 7:30 am to 3:30 PM. To eliminate redundant data maintenance, you want to use a reference capacity to model this.

Unit 5: Modeling the Manufacturing Process

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Field

Entry

Description

Assembly line ##

Person responsible

0##

Usage

009 (All task list types)

Standard value key

SAP1 (Normal production)

Rules for maintenance

Setup time - no checking Machine time - no checking Labor time - no checking

o n l y

C S C

4.

Add the reference capacity REF-##. Enter the capacity category 001, Setup Formula SAP005, and Processing Formula SAP006.

5.

Maintain the Scheduling tab page with the following data:

i n t e r n a l

Scheduling basis: Capacity category

001

Setup formula

SAP001

Processing formula

SAP002

C S C

Maintain the following data on the Costing tab page: Field

Entry

Cost center

4230

Activity type

o n l y

F o r

Entry

b y

6.

Field

u s e

u s e

On the Default values tab page, choose the control key and minutes as the unit of measure.

Setup time -1422 Machine time -1420

Formula keys

Setup - SAP005 Machine - SAP006

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i n t e r n a l

3.

b y

F o r

Performance efficiency rate key

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Lesson: Capacities in the Work Center

Solution 10: Capacities in the Work Center Task 1: Create Reference Resource Your assembly lines run from 7:30am to 3:30pm. Each line is available 95% of the time, due to preventive maintenance. Create a reference capacity to model this. Create a machine capacity, REF - ##, Assembly Lines, that will reflect the master data above, and model you high-speed filling line master data. a)

Choose Logistics → Production → Master Data → Work Centers → Capacity → Create.

b)

Enter the following data: Entry

Plant

1000

Capacity

REF - ##

Capacity Category

001 - Machine

b y

Select Header data (enter)

Field

Entry

Capacity Description

Assembly Lines

Capacity planner grp

2##

Pooled capacity

deselect

Grouping

99 - APO

Factory calendar ID

US

Active version

01 - Normal Capacity

Base unit of meas.

H - Hours

Start

07:30:00

Finish

15:30:00

Length of breaks

00:00:00

Capacity Utilization

95

No. indiv. cap.

1

Relevant to finite scheduling

Select

C S C

i n t e r n a l

Enter the following data in the capacity header:

b y

o n l y

F o r

.

u s e

u s e

c)

i n t e r n a l

C S C

Field

F o r

o n l y

1.

Can be used by several operations Deselect Continued on next page

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d)

Choose Save

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.

Task 2: Pooled Capacity in mySAP SCM You are staffed with six operators to run the assembly lines. Model these as a pooled capacity.

a)

Choose Logistics → Production → Master Data → Work Centers → Capacity → Create.

b)

Enter the following data: Field

Entry

Plant

1000

Capacity

Pool - ##

Capacity Category

002 - Labor

i n t e r n a l

C S C

Create a pooled capacity, Pool - ##, that will represent the labor force that is responsible for running the assembly lines in plant 1000, based on the figures above.

F o r

o n l y

1.

GR ## Operators

Capacity Planner grp

2##

i n t e r n a l

Pooled capacity

Select

Grouping

99 - APO

Factory Calendar ID

US

Active Version

01 - Normal Avail Capacity

Base unit of meas.

H - Hour

Start

07:30:00

Finish

15:30:00

Length of breaks

01:00:00

Capacity Utilization

100

No. of indiv. cap

6

Relevant to finite sched.

Select

u s e

Description

b y

Entry

u s e

Field

F o r

b y

Select Header data (enter) .

C S C

o n l y

Can be used by several operations Select Continued on next page

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Lesson: Capacities in the Work Center

c)

Choose Save .

Task 3: Create a Work Center Create work center Assy-## in plant 1000. The work center will use the reference capacity REF-## and pooled capacity Pool-##.

b y

a)

Choose Logistics → Production → Master Data → Work Centers → Work Center → Create.

b)

Enter plant 1000, work center number Assy-##, and work center category 0003.

c)

Choose Enter

Enter the following data on the Basic data tab page: Field

Entry

Description

Assembly line ##

Person responsible

0##

Usage

009 (All task list types)

Standard value key

SAP1 (Normal production) Setup time - no checking

u s e

Rules for maintenance

u s e

.

i n t e r n a l

C S C

2.

Create work center Assy-## in plant 1000.

F o r

o n l y

1.

Machine time - no checking

C S C

i n t e r n a l

b y

Labor time - no checking Performance efficiency rate key

F o r

Confirm entries with Enter. Hint: After the work center number, enter the work center description Assembly line ##. Use the input help to enter the person responsible, usage, and standard value key. Caution: Do not save or exit the work center at this time.

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a)

Unit 5: Modeling the Manufacturing Process

3.

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On the Default values tab page, choose the control key and minutes as the unit of measure. a)

Choose Next screen or choose the Default Values tab.

b)

Maintain the following data on the Default Values tab page: Field

Entry

Control key

PP01

Unit of measure for standard values

Minute

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

Continued on next page

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Lesson: Capacities in the Work Center

4.

Add the reference capacity REF-##. Enter the capacity category 001, Setup Formula SAP005, and Processing Formula SAP006. a)

Select the Capacities tab.

b)

Enter Capacity category 001, Setup Formula SAP005, and Processing Formula SAP006.

c)

To access the capacity header data, double-click the number of the capacity category, or choose the Capacity header data button.

d)

Choose: Extras → Reference avail cap.

C S C

Entry

Plant

1000

Capacity

REF-##

Capacity Category

001

Choose Enter .

e)

Arrow back

f)

Choose Create capacity .

to the Change work center: Capacity Overview screen.

i n t e r n a l

F o r

Capacity category

002

Pooled capacity

Pool-##

Setup Formula

SAP005

Processing formula

SAP007

o n l y

Entry

C S C

5.

Field

b y

Enter the following and confirm with Enter:

Maintain the Scheduling tab page with the following data:

Continued on next page

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u s e

u s e

b y

Note: Notice that the fields cannot be changed since they are from the reference capacity.

i n t e r n a l

Field

F o r

o n l y

Enter the following:

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Unit 5: Modeling the Manufacturing Process

Field

Entry

Scheduling basis: Capacity category

001

Setup formula

SAP001

Processing formula

SAP002

a) 6.

PLM114

Confirm with Enter .

Maintain the following data on the Costing tab page: Field

Entry

Cost center

4230 Setup time -1422

F o r

o n l y

Activity type

Machine time -1420

C S C

i n t e r n a l

Formula keys

Setup - SAP005

a)

Select the Costing tab.

b)

Make the required entries from the table above.

c)

Save your work center by choosing Save

u s e

.

b y

i n t e r n a l

u s e

b y

Machine - SAP006

C S C

F o r

o n l y

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Lesson: Capacities in the Work Center

Lesson Summary You should now be able to: • Describe the function of a pooled work center • Describe a reference work center • Use reference and pooled capacities

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

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Lesson: Integrating Costing with the Work Center Lesson Overview In this lesson we will describe the integration between costing and the work center.

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

Describe the how the work center integrates with costing Demonstrate how the work center and the task list interact with the cost center

o n l y

C S C

b y

Cost Center Assignment and Integration

u s e

b y

i n t e r n a l

u s e

For operation costing, it is necessary to assign the work center to a cost center. Additionally, activity types with cost unit rates are required because multiple work centers can belong to one cost center.

i n t e r n a l

As the engineer/planner responsible for maintaining work centers, you must be aware of the integration between the work center, the task list, and the cost center. Work centers will only be created periodically after the initial go live of your implementation. You need learn how the initial setup parameters will be continually integrated with the cost accounting module of SAP ERP.

F o r

Business Example

C S C

F o r

o n l y

Figure 102: Production Costing

You can assign a work center to only one cost center in a time period. A cost center, however, can contain several work centers.

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Lesson: Integrating Costing with the Work Center

You must enter the cost center activity types that are relevant to costing in a work center. There must be an activity type master for the activity types used. The activity types maintained in the work center are used as default values for the operation. If no reference indicator has been set for the activity type in the work center, you can change the activity type in the operation.

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

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Lesson Summary You should now be able to: • Describe the how the work center integrates with costing • Demonstrate how the work center and the task list interact with the cost center

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

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Lesson: Configuring the Work Center

Lesson: Configuring the Work Center Lesson Overview In this lesson you will learn about the work center category, the field selection control, and the default work center. You will also learn how to configure scheduling, including the formulas, standard value keys, and the corresponding check tables.

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

o n l y

Define default values for work centers Explain the configuration settings regarding work centers Create and test work center formulas

F o r

• • •

u s e

C S C

u s e

b y

Your company has set some requirements that certain fields in the work center be made required entries in order to save a work center. As the project team member responsible for implementing work centers in SAP ERP, r. you must become familiar with how to configure the work center.

Work Center Category

b y

The work center category is the central control element for work center maintenance.

C S C

i n t e r n a l

i n t e r n a l

Business Example

F o r

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o n l y

F o r

C S C

You use the task list application to define which departments can use the work center.

b y

If you activate creation of change documents, you can trace changes to the work center.

u s e

i n t e r n a l

The order of the screens can be specified for each work center category by using screen sequence control.

F o r

Work Center Configuration: Default Work Center You can create a default work center for each plant and work center category.

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o n l y

The default work center makes work center maintenance easier and can be defined per plant and work center category.

C S C

Field selection control lets you define, field-by-field, which fields are ready for input, display only, highlighted, or hidden.

b y

You can also use the work center category to control the color in which a work center is shown in a hierarchy graphic.

u s e

You can assign a user status profile to the work center category. To maintain a user status profile, use transaction BS02.

i n t e r n a l

Figure 103: Configuring Work Centers: Work Center Category

PLM114

Lesson: Configuring the Work Center

C S C

If you create a work center with a copy template, the default work center is irrelevant.

b y

Work Center Configuration: Screen Control

u s e

b y

i n t e r n a l

u s e

You can define a separate screen sequence for each work center category. Several work center categories can use the same screen sequence.

i n t e r n a l

If you create a work center without a template, and a default work center exists, the default work center is used. All screens are blank if no default work center has been created for the work center category and plant.

F o r

o n l y

Figure 104: Configuring Work Centers: Default Work Center

C S C

F o r

o n l y

Figure 105: Configuring Work Centers: Screen Control

The screen sequence controls which views are to appear in which order, and which views are required for checking the routing. The screen sequence always starts with the basic data. The basic data is always mandatory. All other screens can be selected as and when required, can be numbered and sorted in any order, and can be mandatory if you so decide.

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The structure of screens (for example, the subscreens) cannot be influenced by Customizing (as is possible for the material master record). Note: Mandatory data: This indicator is relevant to the check work center function in work center maintenance only. If you have not yet processed a screen of the work center and execute the Check work center function, you see one of the following messages: “Data is still to be maintained”, if the indicator for the screen is set. “Data should still be maintained”, if the indicator for the screen is not set.

Work Center Configuration: Field Control

o n l y

F o r

You can define a separate field control for each work center category. Several work center categories can use the same field selection.

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

Figure 106: Configuring Work Centers: Field Selection Control

The field control is defined for each screen of the work center.

F o r

You can define the setting for each field as general, meaning the same for all work center categories. You can also define this specifically for one work center category, meaning . for one type of field selection. You can produce a list of the settings for each field.

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o n l y

For each screen, you see the fields for which you can set the display.

PLM114

Lesson: Configuring the Work Center

You can define the following settings for a field: • • • • •

Hide completely Display only (here, for example, fix the field contents by forcing a value from the default work center) Ready for input Ready for input and required In addition, you can highlight the field

Control Key The control key is the central control element of the process.

o n l y

F o r

u s e

u s e

b y

C S C

i n t e r n a l

Figure 107: Control Key

C S C

i n t e r n a l

b y

The control key is a required field for the process. The control key can originate from the work center, either as a reference or as a proposal.

F o r

o n l y

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You use the control key to define whether an operation (also suboperation, activity element, phase, or secondary resource): • • • • •

b y

C S C

• •

– = internally processed – “+” = externally processed – “X” = internally processed / can be processed externally Can be considered in scheduling (indicator Sched. external op.) Supports confirmation:

b y

u s e

C S C

i n t e r n a l

= possible, but not required 1 = milestone confirmation 2 = required 3 = impossible

u s e

– – – –

i n t e r n a l

•

– Prints time tickets ( Print indicator must be set first) – Prints confirmation slips ( Print indicator must be set first) Is processed externally

F o r

o n l y

•

Is read in scheduling Is read in capacity planning Is read in worklists in quality management (inspection characteristics) Is read in costing Automatically posts a goods receipt if a confirmation is entered for this operation Prints related shop floor papers (Print indicator), where this is defined for the order type, plant, and MRP controller, and where the control key is checked when printing shop floor papers:

F o r

o n l y

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Lesson: Configuring the Work Center

Standard Value Key

b y

Step 1: Check the parameters defined. For standard value keys, only parameters with the original two standard values of operation can be used.

b y

u s e

C S C

i n t e r n a l

u s e

Step 2: Define the standard value key. You use this to define how many of the maximum of six standard values are used. By assigning parameters to the individual elements of the standard value keys, you define the meaning of the individual standard values, including dimension, unit of measure, format, and description.

i n t e r n a l

C S C

o n l y

F o r

Figure 108: Standard Value Key

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Configuration of Scheduling Including Formulas

b y

u s e

b y

i n t e r n a l

If splitting takes place, you must also take into account the formula parameters in the formula for the number of splits.

u s e

The standard values defined for the routing and the formulas defined in the work center are used in lead-time scheduling to calculate the execution time for the individual segments (setup, processing, and teardown).

i n t e r n a l

C S C

o n l y

F o r

Figure 109: Execution Time

C S C

F o r

o n l y

Figure 110: Formulas

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Lesson: Configuring the Work Center

Formulas can be assigned to each capacity in the work center to calculate the capacity requirement. At the same time, formulas can also be permitted for different functions (capacity requirement, scheduling, and costing). Generation controls the immediate code generation for the formula. If no code is generated in formula maintenance, it is generated at execution time. There is a maximum of three lines per formula. Possible arithmetical operations are +, -, *, /, SIN, COS, DIV, MOD, SQRT, EXP, and LOG. Conversion of units of measure takes place automatically.

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

Figure 111: Setting Up Formulas

C S C

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Formula parameters are differentiated according to their origin. The following origins for a formula parameter can be defined in Customizing: •

• • •

o n l y

C S C

b y

•

u s e

b y

i n t e r n a l

u s e

Capacity Categories and Capacities, Including Shift Sequences

i n t e r n a l

•

F o r

•

General operation value: The parameter is linked to a field in the general operation data. The value of this field is entered in the formula. Typical fields are lot size, base quantity, number of splits (partial lots), and number of employees. Work center constant: The parameter is assigned a constant value in the work center. This value is used in the formula. Standard value: Using the standard value key, you can assign a standard value that is used as a parameter in the formula. User field in the operation: The value of a custom field in the operation is assigned to the parameter. Value from PRT assignment: This could be either the quantity or the usage value of the production resource/tool (PRT). This parameter can only be used for formulas that are used for PRT management. PRT constant: You assign a constant value to this parameter in the PRT master record. These formula parameters can only be used in formulas for PRT management. General formula constant: A value is assigned to this parameter, which is then used in the application.

C S C

F o r

o n l y

Figure 112: Capacity Categories and Capacities

• •

262

Creating capacities Assigning capacities to a work center, including intervals of available capacity, shift sequences, shifts, and so on

© 2006 SAP AG. All rights reserved.

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PLM114

Lesson: Configuring the Work Center

b y

The data in the environment for defining shift sequences can be grouped. This helps structuring and selection.

C S C

3.

b y

i n t e r n a l

2.

Create the work break schedules. Work break schedules can contain several breaks. A break is a time interval at a fixed time or at a time relative to the start of the shift, which is defined later. Define the individual shifts. A shift is a fixed time interval. You can assign a work break schedule to a shift. From this time interval and the breaks within the assigned work break schedule, the working time is calculated. Define the shift sequences. A shift sequence can consist of several lines (shift numbers). For each line, you can assign a shift from step 2 to each weekday.

u s e

u s e

1.

i n t e r n a l

C S C

o n l y

F o r

Figure 113: Shift Sequences

F o r

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Other Check Tables

o n l y

F o r

C S C

b y

These check tables are found in Customizing, and some of them can also be found also in the work center menu by choosing Environment → Current settings.

b y

i n t e r n a l

u s e

u s e

Suitability and wage group are parameters from human resources. These are defined here if you do not use the SAP solution for human resources.

i n t e r n a l

Figure 114: Other Check Tables

C S C

F o r

o n l y

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Lesson: Configuring the Work Center

Exercise 11: Optional: Work Center Formulas Exercise Objectives After completing this exercise, you will be able to: • Create and test formulas

Business Example As a member of the project team, you are responsible for feasible and exact scheduling of the company’s products

o n l y

F o r

You first need to set up formulas.

C S C

First define a formula parameter for the additional setup time and a formula parameter for the period, expressed as a quantity, after which the setup is to be repeated. The parameter values should have their origin in a standard value in the operation.

Parameter

SAP1##

SAP2##

Parameter Text

Perd. Set-up

Sinterval

Keyword

PS group ##

SI group ##

Dimension

Time (TIME)

Without dimensions (AAADL)

Standard value unit

1 Minutes (MIN)

Piece(PC)

Define a formula for periodic setup at your work center. Call the formula SAP1## with the description PS group ##. This formula must be valid only for scheduling and must be generated immediately when you save. Use the parameters from the table for this. Continued on next page

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o n l y

F o r

Sinterval

C S C

Periodic Setup

Standard value

2.

b y

i n t e r n a l

Data for the group parameters:

u s e

u s e

1.

i n t e r n a l

Create a formula for periodically repeating setup at a work center. To be able to create and test the formula, it is necessary not just to define the formula parameters for the formula, but also to define a standard value key that supplies the formula with values.

b y

Task 1:

Unit 5: Modeling the Manufacturing Process

PLM114

The formula is Machine * Operation quantity / Base quantity + Periodic setup * ( (Operation quantity – 1 ) / Setup interval ). 3.

Define a new standard value key so that the parameters in the formula can be supplied with values. The standard value key should allow entries for setup time, machine time, and additional setup after 50 pieces. The key name is S## with the description SI group ##.

Task 2:

o n l y

Replace the processing formula key for execution time with the formula key SAP1## that you created. Note the warning messages after you have confirmed the entry.

3.

In the previous step, you saw a warning message, and you now want to respond to this. Make the relevant change in your work center.

4.

Now test your formula on the Scheduling screen. Enter the following values:

i n t e r n a l

Operation quantity

101 pieces

Setup time

10 minutes

Machine time

1 minute

PS group ##

5 minutes

SI group ##

50 pieces

C S C

Entry

b y

Field

u s e

u s e

b y

2.

i n t e r n a l

Create a new work center, PL##, with work center category PL##. Copy the Basic data, Default values, Capacities, and Scheduling screens from work center 1905. The description of the work center is Formula test ##. Save the work center.

F o r

1.

C S C

Test the formulas on the scheduling screen of a new work center.

F o r

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Lesson: Configuring the Work Center

Solution 11: Optional: Work Center Formulas Task 1: Create a formula for periodically repeating setup at a work center. To be able to create and test the formula, it is necessary not just to define the formula parameters for the formula, but also to define a standard value key that supplies the formula with values. First define a formula parameter for the additional setup time and a formula parameter for the period, expressed as a quantity, after which the setup is to be repeated. The parameter values should have their origin in a standard value in the operation.

F o r

o n l y

1.

b y

Sinterval

Parameter

SAP1##

SAP2##

Parameter Text

Perd. Set-up

Sinterval

Keyword

PS group ##

SI group ##

Dimension

Time (TIME)

Without dimensions (AAADL)

Standard value

Piece(PC)

a)

In Customizing, choose Production → Basic data → Work center → General data → Standard value → Define parameters.

b)

Choose the New Entries button.

c)

Enter the parameters according to the table with origin key 2.

Define a formula for periodic setup at your work center. Call the formula SAP1## with the description PS group ##. This formula must be valid only for scheduling and must be generated immediately when you save. Use the parameters from the table for this.

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o n l y

F o r

Minutes (MIN)

C S C

2.

1

b y

i n t e r n a l

Standard value unit

u s e

u s e

Periodic Setup

i n t e r n a l

C S C

Data for the group parameters:

Unit 5: Modeling the Manufacturing Process

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The formula is Machine * Operation quantity / Base quantity + Periodic setup * ( (Operation quantity – 1 ) / Setup interval ). a)

In Customizing, choose Production → Basic data → Work center → Capacity planning → Work center formulas → Set up work center formula definition.

b)

Choose the New Entries button.

c)

Enter the Formula key SAP1## and Description PS–Group ##. Hint: •

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e)

Set the Generate and Allowed for scheduling flags.

Define a new standard value key so that the parameters in the formula can be supplied with values. The standard value key should allow entries for setup time, machine time, and additional setup after 50 pieces. The key name is S## with the description SI group ##.

b)

Choose the New Entries button.

c)

Enter the Standard value key S## and the Description SI Group ##.

d)

Field

Entry

Setup time

SAP_01

Machine time

SAP_02

PS group ##

SAP1##

SI group ##

SAP2##

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F o r

Include the following parameters in the standard value key:

Choose Save.

Continued on next page

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In Customizing, choose Production → Basic data → Work center → General data → Specify standard value key.

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a)

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Enter the formula SAP_02 * SAP_09 / SAP_08 + SAP1## * ( ( SAP_09 - 1 ) DIV SAP2## ).

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3.

d)

F o r

• •

You determine the necessary parameter ID by means of the search field for parameters. Upper/lowercase and line breaks do not affect the formula. Insert a blank before and after special characters (operators).

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Lesson: Configuring the Work Center

Task 2: Test the formulas on the scheduling screen of a new work center. 1.

Create a new work center, PL##, with work center category PL##. Copy the Basic data, Default values, Capacities, and Scheduling screens from work center 1905. The description of the work center is Formula test ##. Save the work center. a)

From the SAP Easy Access screen, choose Logistics → Production → Master data → Work centers → Work center → Create .

C S C

Work Center

P-##

Work center category

PL##

Reference plant

1000

Reference work center

1905

b y

1000

Choose Enter.

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Plant

=> Window “copy template”

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Entry

Copy = Enter

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Field

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Enter the data from the table below.

Ignore the warning message (different work center category).

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Basic data, Defaults, Capacities and Scheduling

b y

=> Basic data screen

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Description: Formula test ## => Costing -> Cancel = F12 ( back to Basic data screen) & save

F o r

Replace the processing formula key for execution time with the formula key SAP1## that you created. Note the warning messages after you have confirmed the entry. a)

Without leaving this screen, choose Work center → Change.

b)

Choose the Scheduling button.

c)

Overwrite the key SAP003 with your formula key, SAP1xx.

d)

Choose Enter. You will receive warning messages. Continued on next page

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Unit 5: Modeling the Manufacturing Process

3.

In the previous step, you saw a warning message, and you now want to respond to this. Make the relevant change in your work center. a)

Now test your formula on the Scheduling screen. Enter the following values: Field

Entry

Operation quantity

101 pieces

Setup time

10 minutes

Machine time

1 minute

PS group ##

5 minutes

SI group ##

50 pieces

Go back to the Scheduling tab page and choose the Test formula button. Enter the values from the exercise and choose Calculate.

b)

The calculated overall execution time is 121 minutes, so setup was repeated twice.

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a)

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Without leaving this screen, go to the Basic data tab page and overwrite the standard value key SAP1 with S##.

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Lesson: Configuring the Work Center

Exercise 12: Work Center Category and Field Selection Control, Default Work Center (Optional) Exercise Objectives After completing this exercise, you will be able to: • Set up a work center with a separate screen sequence • Set up a work center with a separate field sequence • Set up a work center category with a default work center

o n l y

You are responsible for the system settings for work centers. A new work center category is to be set up for work centers in discrete manufacturing.

1.

Use work center category number PL## and the description Category ##.

2.

Set up the work center category for the task list application Routings for production.

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Task 3:

1.

Hide the Transition matrix field on the basic data tab page, and define the field Person responsible as a required field.

2.

Hide the Other formula and Internal distribution fields on the capacities tab page.

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For your work center category PL##, set the following screen selection sequence: basic data, defaults, capacities, scheduling, costing, and technology. Apart from the basic data, no other views need to be required.

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Adapt the field selection control for work center category PL## on tab pages Basic data and Capacities according to your requirements as follows:

1.

b y

Define a special screen sequence for work center category PL##.

F o r

Task 2:

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b y

Create a new work center category for your area of responsibility.

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Task 1:

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Business Example

Unit 5: Modeling the Manufacturing Process

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Task 4: Assign screen sequence and field selection to a work center category. 1.

Assign the screen sequence and field selection you have created to your work center category PL##.

Task 5: Create a default work center in plant 1000 for the work center category PL## you defined in the first task.

b y

u s e

All task list types

Standard Value Key

Normal production

Maintain the following data on the Default values tab page: Control key

Choose one of the PP series control keys (PP01, PP02 through PP99). It must allow scheduling, capacity planning, and costing. It must also print time tickets and allow confirmations.

Units of measure for standard values

Minute

u s e

3.

Maintain capacity category machine on the Capacities tab page:

4.

Create a work center in plant 1000 to check the settings for the screen sequence and field selection.

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Task list usage

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2.

Maintain the following data on the Basic data tab page:

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Lesson: Configuring the Work Center

Solution 12: Work Center Category and Field Selection Control, Default Work Center (Optional) Task 1: Create a new work center category for your area of responsibility. 1.

Use work center category number PL## and the description Category ##. a)

In Customizing, choose Production → Basic data → Work center → General data → Define work center category.

PL##

Description

Category ##

Save.

b y

2.

Set up the work center category for the task list application Routings for production. a)

Select your new line and choose Application in the dialog structure.

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Click New Entries for the selection of application P.

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Cat.

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Choose New Entries.

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Choose Save.

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F o r

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Task 2: Define a special screen sequence for work center category PL##. 1.

For your work center category PL##, set the following screen selection sequence: basic data, defaults, capacities, scheduling, costing, and technology. Apart from the basic data, no other views need to be required. a)

In Customizing, choose Production → Basic data → Work center → Set up work center screen sequence.

C S C

Default values

3

Capacities

4

Scheduling

5

Costing

6

Technology

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2

F o r

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Make the following entries for work center category PL##:

Delete the numbers of screens that are not required.

b y

Choose Save.

Adapt the field selection control for work center category PL## on tab pages Basic data and Capacities according to your requirements as follows:

a)

In Customizing, choose Production → Basic data → Work center → General data → Define field selection.

F o r

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Select the screen group Basic data and select influencing. Use your work center category PL## as the value for influencing, then make absolutely sure you choose Enter. Set the Transition matrix field to hide and the Person responsible field to required entry.

C S C

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Hide the Transition matrix field on the basic data tab page, and define the field Person responsible as a required field.

b y

1.

u s e

u s e

Task 3:

PLM114

Lesson: Configuring the Work Center

2.

Hide the Other formula and Internal distribution fields on the capacities tab page. a)

Push-button Screen group Select the screen group Capacity and select influencing. Use your work center category PL## as the value for influencing, then make absolutely sure you choose Enter button. Set the Other formula and Internal distribution fields to Hide. Choose Save.

Task 4: Assign screen sequence and field selection to a work center category.

o n l y

Assign the screen sequence and field selection you have created to your work center category PL##. In Customizing choose, Production → Basic data → Work center → General data → Define work center category. Assign field selection PL## and screen sequence PL## to your work center category PL##.

b y

Choose Save.

u s e

1.

Maintain the following data on the Basic data tab page:

b y

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Create a default work center in plant 1000 for the work center category PL## you defined in the first task.

u s e

Task 5:

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a)

F o r

1.

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F o r

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Task list usage

All task list types

Standard Value Key

Normal production

a)

In Customizing, choose Production → Basic data → Work center → General data → Define default work center. Plant

1000

Work center category

PL##

Task list usage

009

Standard Value Key

SAP1

F o r

o n l y

Continue with Enter or push-button Basic Data (F5).

b y

C S C

Choose one of the PP series control keys (PP01, PP02 through PP99). It must allow scheduling, capacity planning, and costing. It must also print time tickets and allow confirmations.

Units of measure for standard values

Minute

a)

F o r

Maintain capacity category machine on the Capacities tab page: a)

o n l y

3.

Switch to the Default values tab page. Control key, for example PP01. Switch to the Capacities tab page. Capacity Category: 001 Choose Save.

Continued on next page

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C S C

Control key

b y

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Maintain the following data on the Default values tab page:

u s e

u s e

2.

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Hint: In the field selection control for work center category PL##, you defined that the Person responsible field must always be maintained. The default work center is an exception, compared with ordinary work centers.

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Lesson: Configuring the Work Center

4.

Create a work center in plant 1000 to check the settings for the screen sequence and field selection. a)

From the SAP Easy Access screen, choose Logistics → Production → Master data → Work centers → Work center → Create. Plant

1000

Work Center



Work center category

PL##

Choose Enter.

o n l y

Person responsible is now mandatory.

C S C

Select the Capacities tab.

b y

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u s e

u s e

b y

Note: The Internal Distribution and Other Formula fields are hidden.

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b)

F o r

Note: Info message: “Values were set from the default work center.”

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Lesson Summary You should now be able to: • Define default values for work centers • Explain the configuration settings regarding work centers • Create and test work center formulas

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Unit Summary

Unit Summary

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F o r

You should now be able to: • Describe the purpose and integration points of the task list (routing) • Describe the structure and purpose of the work center • Describe the purpose of the standard value key and standard values • Describe the purpose of defaults in the work center • Create standard texts to describe a process step • Describe capacities and demonstrate their maintenance • Describe the function of a pooled work center • Describe a reference work center • Use reference and pooled capacities • Describe the how the work center integrates with costing • Demonstrate how the work center and the task list interact with the cost center • Define default values for work centers • Explain the configuration settings regarding work centers • Create and test work center formulas

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© 2006 SAP AG. All rights reserved.

Unit 6 Task Lists Unit Overview

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C S C

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

b y

C S C

b y

u s e

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Describe the different types of task lists Describe the integration points of the task list Assign manufactured items to routings Allocate material components to operations Maintain cutting measures of variable-size items Describe the functions of suboperations Retrieve additional fields in operations Demonstrate how to make changes with history Demonstrate how to use where-used lists and mass changes Define system settings for routings

u s e

• • • • • • • • • •

F o r

Lesson: Overview of the Task List ............................................282 Exercise 13: Create a Simple Routing...................................287 Lesson: Creating a Routing and Material Assignment .....................296 Exercise 14: Material Assignment and Component Allocation .......301 Lesson: Suboperations and User-Defined Fields...........................307 Exercise 15: Suboperations for Material-Specific Capacity Constraints .................................................................. 311 Lesson: Reporting and Mass Changes ......................................315 Exercise 16: Task List Changes with ECM..............................321 Lesson: Configuring the Routing..............................................327

© 2006 SAP AG. All rights reserved.

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Unit Contents

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F o r

This unit introduces the basic concept of the SAP ERP task list (routing). You will be instructed on the creation, maintenance, and configuration of the routing. You will also execute various transactions to manage the process surrounding its life cycle. Several advanced functions will be covered in another lesson.

Unit 6: Task Lists

PLM114

Lesson: Overview of the Task List Lesson Overview In this lesson, you will learn about task lists in SAP ERP. We will discuss the different types of task lists and their integration points with other parts of the SAP ERP system.

Lesson Objectives After completing this lesson, you will be able to: Describe the different types of task lists Describe the integration points of the task list

F o r

o n l y

• •

Business Example

C S C

b y

C S C

i n t e r n a l

b y

A task list is a non-order-related process for implementing an activity. Task lists are used throughout the SAP ERP system to define a sequence of activities to produce a specific result. Task lists are used in several application areas, including PP, PP-PI, PS, QM, and PM. The following table shows several different types of task lists that are used in the SAP ERP system.

u s e

u s e

Task Lists Types

i n t e r n a l

As the project lead for implementing task lists, you must be aware of the structural design of the task list object in SAP ERP. In doing so, you need to learn how the task list and work center are structured to integrate with several business areas in your company. Your company has requirements to use task lists and work centers for costing, engineering, and production.

F o r

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Lesson: Overview of the Task List

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A routing is made up of operations to which work centers are assigned. The details of the operations contain the standard values or times of production at that work center. They also contain information about each work center where the work is to

C S C

A routing determines the sequence of individual operations that are necessary to produce a product. It describes the sequence of activities, where the work is performed, and how much of the work center's resources will be consumed. A routing can be created with or without a material number. Routings without material numbers can be used by many materials that all use the same production process, production line, or manufacturing steps.

b y

Structure of a Routing

u s e

Routings describe material-related production and are used in production planning. Reference operation sets are not created for a specific material, but can be used as references within routings or copied into routings. They are usually activities that are common to many routings and can be created with either internal or external numbering. Rate routings describe material-related production using production lines and are used mostly by repetitive manufacturing. Reference rate routings are non-material specific activities that are common to many rate routings and can be used as references within rate routings or copied into them to simplify data entry. Master recipes describe material specific production and are used in production planning for process industries. Rough-cut capacity profiles are used to view resource loads in sales and operations planning without BOM explosion. Networks contain instructions on how to perform tasks in a specific way, in a specific order, and in a specific time period, and are used in project systems. Inspections plans describe the inspection process for a material and are used in quality management.

i n t e r n a l

Figure 115: Task List Types

Unit 6: Task Lists

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be performed. The SAP ERP system stores routings in groups that can be either internally or externally assigned. There can be many routings in a group, each distinguished by a different group counter. Other important assignments in the routing include the materials components from the BOM and any PRTs that are required for production. PRTs are items needed for production that are not consumed like tools and fixtures. More than one BOM can have components allocated to the same routing. Components are assigned to the specific operation where they are needed and consumed in the production process.

o n l y

F o r

Inspection characteristics can be assigned to the operations in the routing if a quality inspection is to be performed during an operation. Trigger points can also be assigned to an operation to trigger functions when a certain event occurs. Examples of such events might be a change in status or the release of an operation based on another event happening, such as a confirmation.

b y

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b y

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F o r

C S C

Figure 116: Routing Structure

Routing Integration A routing is independent of an order and is used in the creation of an order. The operations and information from the routing is copied into the order during order creation. This includes the planned time for each activity within an operation (standard value), the work center, and the control key. The routing information in the order becomes the basis for lead time scheduling, product costing, and capacity planning.

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Figure 117: Routing Usage

C S C

b y

b y

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u s e

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A routing is defined at the plant level. This means that the organizational elements for company code, valuation area, and plant all need to be defined prior to creating a routing. A work center is needed to assign to the operation, so a work center must also exist before the routing can be created. The routing integrates with material master data, BOM components, work centers, as well as product costing, capacity planning, production orders, procurement, and planning.

C S C

F o r

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Figure 118: Routing Integration in SAP ERP

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Lesson: Overview of the Task List

Exercise 13: Create a Simple Routing Exercise Objectives After completing this exercise, you will be able to: • Create a simple routing for a material • Create a group routing that is not material specific

Business Example

F o r

o n l y

Your business is implementing SAP ERP and you must model the manufacturing procedure for material manufacturing. You must create a routing for materials production.

Task 1: Create a simple routing for material production.

C S C

b y

Create a routing for the production of material T-B## in plant 1000 that consists of the four steps in the table below. The routing should be creation status, valid from today's date, for production usage, and for lot sizes from 1 to 100,000 Pc. Use the data in the table below to complete the routing information.

u s e

i n t e r n a l

Work Center

Control Key

Description

10

T-A##

PP01

Lathe casing according to drawing

20

T-B##

PP01

Drill holes

30

T-C##

PP01

Insert Flat gasket

40

T-C##

PP01

Inspect and deliver to stock

C S C

Operation #

o n l y

Standard Processing Times

2.

Activity

Op 10

Op 20

Op 30

Op 40

Setup

10 Min

3 Min

0 Min

0 Min

Machine

30 Min

10 Min

0 Min

0 Min

Labor

30 Min

10 Min

5 Min

10 Min

What are the task list group number and group counter on the header of your routing? Continued on next page

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F o r

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Primary Operation Data

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3.

What is the base quantity and operation unit for operation 10 and how does it relate to the standard values?

4.

Save your routing by choosing Save

.

Task 2: 1.

Display your routing.

2.

What are the group number and group counter?

3.

When was the routing created and by whom?

4.

What are the validity dates for the routing?

5.

What are the validity dates of operation 20?

F o r

o n l y

Display your routing and answer the following questions.

Task 3:

C S C

Create a non-material specific routing for the production of several different pumps in plant 1000 thath all use the same five steps in the table below. The routing should be creation status, valid from today's date, for production usage, and for lot sizes from 1 to 100 only. Use the data in the table below to complete the routing information.

i n t e r n a l

Work Center

Control Key

Description

10

T-M##

PP01

Material Staging

20

T-E##

PP01

Pre-assemble pump

30

T-P##

PP01

In-process inspection

40

T-P##

PP01

Final assembly

50

T-P##

PP99

Deliver to stock

b y

Operation #

F o r

Primary Operation Data

C S C

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Standard Processing Times Activity

Op 10

Op20

Op 30

Op 40

Op 50

Setup

10 Min

30 Min

0 Min

30 Min

0 Min

Machine

0 Min

0 Min

0 Min

10 Min

0 Min

Labor

0 Min

10 Min

5 Min

10 Min

10 Min

Continued on next page

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u s e

u s e

b y

1.

i n t e r n a l

Create a non-material-specific group routing to manufacture many different pumps that all have the same manufacturing process.

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Lesson: Overview of the Task List

2.

What are the task list group number and group counter on the header of your routing?

3.

What is the base quantity and operation unit for operation 10 and how does it relate to the standard values?

4.

Save your routing by choosing Save

.

Task 4: 1.

Display your routing.

2.

What are the group number and group counter?

3.

When was the routing created and by whom?

4.

What are the validity dates for the routing?

5.

What are the validity dates of operation 20?

F o r

o n l y

Display your routing and answer the following questions.

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Solution 13: Create a Simple Routing Task 1: Create a simple routing for material production. 1.

Create a routing for the production of material T-B## in plant 1000 that consists of the four steps in the table below. The routing should be creation status, valid from today's date, for production usage, and for lot sizes from 1 to 100,000 Pc. Use the data in the table below to complete the routing information.

C S C

b y

Work Center

Control Key

Description

10

T-A##

PP01

Lathe casing according to drawing

20

T-B##

PP01

Drill holes

30

T-C##

PP01

Insert Flat gasket

40

T-C##

PP01

Inspect and deliver to stock

i n t e r n a l

Operation #

i n t e r n a l

Op 30

Op 40

Setup

10 Min

3 Min

0 Min

0 Min

Machine

30 Min

10 Min

0 Min

0 Min

Labor

30 Min

10 Min

5 Min

10 Min

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Create or use transaction code CA01.

b)

Enter the material T-B## and plant 1000 and choose Enter

c)

Enter Usage 1 for Production, Status 1 for Creation Phase, Planner group 0##, and lot size of 1 to 100,000 Pc.

d)

Select the Operations Overview icon and enter the Primary Operation Data from the table. Respond to any system messages that appear.

e)

Select all operations and choose Details → Operation from the menu. Enter the Standard Operation Processing Times from the table and to navigate to the next operation detail screen. Continue choose until all times have been entered and then choose to return to the operation overview.

.

Continued on next page

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a)

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Op 20

b y

Op 10

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Standard Processing Times Activity

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Primary Operation Data

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Lesson: Overview of the Task List

2.

What are the task list group number and group counter on the header of your routing? a)

3.

What is the base quantity and operation unit for operation 10 and how does it relate to the standard values? a)

4.

Choose to view the header. The group number should be blank and the group counter is 1.

From the operations overview, double-click on the operation number 0010. You should now be in the details of the operation. The base quantity is 1 PC. The standard values are the setup and labor times required to produce 1 casing.

Save your routing by choosing Save

.

o n l y

F o r

a)

Task 2:

C S C

1.

Display your routing.

b y

a)

u s e

What are the group number and group counter?

3.

When was the routing created and by whom?

F o r

The validity dates should be from today to 12/31/9999 as found in the administrative data section.

What are the validity dates of operation 20? a)

Select and double-click on operation number 20. Scroll to the bottom of the Operation details screen and you will see validity dates identical to those on the header: from today's date to 12/31/9999.

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o n l y

What are the validity dates for the routing? a)

5.

In the header details, scroll to the bottom of the screen. In the administrative data section, you will find today's date for the creation date and your logon as the creator.

C S C

a)

4.

The group number will vary, but should be a number beginning with 50000 and the group counter should still be 1.

b y

i n t e r n a l

a)

u s e

2.

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03. Enter T-B## and plant 1000 and choose .

i n t e r n a l

Display your routing and answer the following questions.

Unit 6: Task Lists

PLM114

Task 3: Create a non-material-specific group routing to manufacture many different pumps that all have the same manufacturing process. 1.

Create a non-material specific routing for the production of several different pumps in plant 1000 thath all use the same five steps in the table below. The routing should be creation status, valid from today's date, for production usage, and for lot sizes from 1 to 100 only. Use the data in the table below to complete the routing information.

Description

o n l y

10

T-M##

PP01

Material Staging

20

T-E##

PP01

Pre-assemble pump

30

T-P##

PP01

In-process inspection

40

T-P##

PP01

Final assembly

50

T-P##

PP99

Deliver to stock

b y

Control Key

i n t e r n a l

Work Center

F o r

Operation #

C S C

Primary Operation Data

b y

i n t e r n a l

u s e

u s e

Standard Processing Times

C S C

F o r

o n l y

Continued on next page

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Lesson: Overview of the Task List

Op 10

Op20

Op 30

Op 40

Op 50

Setup

10 Min

30 Min

0 Min

30 Min

0 Min

Machine

0 Min

0 Min

0 Min

10 Min

0 Min

Labor

0 Min

10 Min

5 Min

10 Min

10 Min

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Create or use transaction code CA01.

b)

Make sure the Material field is blank, enter plant 1000, enter PUMP## in the Group field, and choose Enter .

c)

Enter Usage 1 for Production, Status 1 for Creation Phase, Planner group 0##, and lot size of 1 to 100,000 Pc.

d)

and enter the Select Operations Overview Primary Operation Data from the table. Respond to any system messages that appear.

e)

Select all operations and choose Details → Operations from the menu. Enter the Standard Operation Processing Times from the table and to navigate to the next operation detail screen. Continue choose until all times have been entered and then choose to return to the operation overview.

b y

a)

u s e

What are the task list group number and group counter on the header of your routing?

3.

F o r

Save your routing by choosing Save

.

a)

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o n l y

From the operations overview, double-click on the operation number 0010. You should now be in the details of the operation. The base quantity is 1 PC. The standard values are the setup time required to produce 1 pump.

C S C

What is the base quantity and operation unit for operation 10 and how does it relate to the standard values? a)

4.

to view the header. The group number should be PUMP## Choose and the group counter is 1.

b y

i n t e r n a l

a)

u s e

2.

i n t e r n a l

C S C

Activity

F o r

o n l y

PLM114

Unit 6: Task Lists

PLM114

Task 4: Display your routing and answer the following questions. 1.

Display your routing. a)

2.

What are the group number and group counter? a)

When was the routing created and by whom? a)

C S C

What are the validity dates for the routing?

b y

a) 5.

The validity dates should be from today to 12/31/9999, as found in the administrative data section.

What are the validity dates of operation 20?

b y

i n t e r n a l

Select and double-click on operation number 20. Scroll to the bottom of the operation details screen and you will see validity dates identical to those on the header: from today's date to 12/31/9999.

u s e

a)

u s e

In the header details, scroll to the bottom of the screen. In the administrative data section you will find today's date for the creation date and your logon as the creator.

i n t e r n a l

4.

The group number should still be PUMP## and the group counter should still be 1.

F o r

o n l y

3.

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03. Make sure the material field is blank and enter plant 1000, group PUMP##, and choose .

C S C

F o r

o n l y

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PLM114

Lesson: Overview of the Task List

Lesson Summary You should now be able to: • Describe the different types of task lists • Describe the integration points of the task list

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

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i n t e r n a l

C S C

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Lesson: Creating a Routing and Material Assignment Lesson Overview In this lesson, you will learn how to assign materials to routings, allocate materials components to specific operations on the routing, and to specify the dimensions of variable-size components.

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

o n l y

Assign manufactured items to routings Allocate material components to operations Maintain cutting measures of variable-size items

F o r

• • •

C S C

As a production planner you are responsible for the correct staging of material components for each operation in production. Therefore you have to assign these components to operations and, if necessary, adjust the BOMs.

b y

Material Assignment

u s e

i n t e r n a l

C S C

Materials can be linked to routings for the following scenarios:

b y

A material master record must exist in the system for the material that is to be produced. It must have a material type that is allowed for assignment to a routing or rate routing.

u s e

You use this function to determine which material is to be produced with a routing or rate routing. On the basis of this assignment, the routing can be used for sales and operations planning, material requirements planning, creating production orders and product costing for this material.

i n t e r n a l

Business Example

F o r

o n l y

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Lesson: Creating a Routing and Material Assignment

o n l y

F o r

C S C

b y

The same routing can be used to produce several different materials. Each product has its own unique bill of material but is manufactured by a common set of activities with the same standard times. For example, both red and green chairs can be produced using the same routing.

u s e

i n t e r n a l

F o r

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o n l y

If you have created a non-material specific routing or a group routing you can use the material assignment. In the header of the routing, the material assignment button will show you a list of all materials that are assigned to use this routing for their production. It allows you to assign more materials to the list. This is also effective for using a routing created for one material to produce a different material. The assignment could be for a material in a different plant, which allows you to plan production in one plant and produce in another.

C S C

If you create a routing for a specific material the material assignment is automatically done by the system. No further settings are necessary and every order created finds this routing assignment and uses the appropriate routing to create the order. This process will be discussed further in the routing configuration lesson.

b y

The material assignment can be done three different ways. You can create the routing for a specific material, use the material assignment functionality in the routing header, or you can use a production version.

u s e

The material and routing can belong to different plants, for example, the planning plant and the production plant may not be the same.

i n t e r n a l

Figure 119: Multiple Products - One Routing

Unit 6: Task Lists

PLM114

The third option is to use a production version. A production version specifies the production technique that can be used to produce a material. It specifies the BOM and routing used for production with date and lot size validities. In this case you must also set the selection method field on the MRP4 view of the material master to select by production version.

Component Allocation Component allocation determines when materials are to be made available to production and consumed in your production process. The shop floor papers will indicate the work center and time to deliver the component to the specific operation to which it was assigned. As production is completed and confirmations are recorded this allocation will also control the consumption of the components.

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

Figure 120: Material Assignment

F o r

• • •

o n l y

The following data must already exist in the system: The operations in the routing. The master record for the material to be produced. The bill of material (BOM) for the material to be produced.

You can assign and display material components for separate operations in the material component overview. For a clearer overview, you can use different criteria to filter or sort the material component list.

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Lesson: Creating a Routing and Material Assignment

You can • • •

Assign a new component Delete and reassign material assignments Navigate between multiple operations

Material components in a BOM that are not assigned to an operation in the routing are automatically assigned (default) to the first operation when you create a production order.

b y

o n l y

C S C

b y

u s e

When you maintain the BOM, the final measurements are specified for the variable-size items.

F o r

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299

o n l y

If you require a large cutting measure for the production of this BOM item, you can specify this when you assign the operation. Only those involved in material staging get these measurements. Inventory management books out the measurements from the BOM.

C S C

i n t e r n a l

Variable-Size Item Calculations in the Routing

u s e

By repeating this process, you can assign material components from several BOMs or alternative BOMs to the same routing . In this case, when you create a production order, you select the BOM and thus which material components are to be assigned in the production order. The system can do this automatically, depending on the system settings.

i n t e r n a l

According to the item category of the assigned components you can make further decisions about their processing, for example, backflushing of stock items or cutting size of variable-size items (discussed in next section).

F o r

Each item on the BOM can be assigned to only one operation. Items which have quantities of more than one and need to be assigned to more than one operation will need to be adjusted in the BOM to allow this type of allocation. For example, BOM item 10 has 2 pieces one of which is used at operation 20 and the other at operation 40. This will necessitate splitting BOM item 10 into 2 BOM items each with quantity of one, say item 10 and item 15. Then item 10 can be allocated to operation 20 and item 15 can be allocated to operation 40.

PLM114

F o r

o n l y

Unit 6: Task Lists

Figure 121: Variable Size Items

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

300

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PLM114

Lesson: Creating a Routing and Material Assignment

Exercise 14: Material Assignment and Component Allocation Exercise Objectives After completing this exercise, you will be able to: • Assign materials to routings • Assign material BOM components to specific operations on the routing • Enter dimensions for variable sized components

Business Example

o n l y

C S C

b y

1.

u s e

u s e

Display the material assignment of your T-B## routing. Display the material assignment for your T-B## routing.

Assign materials to your group routing. Assign the materials T-F1## and T-F2## to your group routing PUMP##.

Task 3:

F o r

1.

First, create a plant-specific BOM for T-B## in plant 1000. Use the BOM T-B1## as a template.

2.

Assign material components from the BOM of T-B## to specific operations on the routing. Assign components T-T2## and T-T3## to operation 30.

Continued on next page

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301

o n l y

Assign material components from the BOM to specific operations on the routing.

C S C

i n t e r n a l

b y

Task 2: 1.

i n t e r n a l

Task 1:

F o r

Several different models of pumps use the same manufacturing steps in production and can use the same routing. You need to assign materials T-F1## and T-F2## to your PUMP## group routing. To make the manufacturing process more efficient, you want to assign material components from the BOM to specific operations on the routing to ensure they are delivered to the correct work center at the correct time. One of your components is a variable sized item and needs to have the specific dimensions defined.

Unit 6: Task Lists

PLM114

Task 4: Assign components to specific operations on your group routing. 1.

Assign the material components from T-F1## to specific operations on your group routing PUMP##. Assign components T-B1## and T-T3## to operation 40, and T-B2##, T-B3##, and T-B4## to operation 20 of your group routing PUMP##.

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

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PLM114

Lesson: Creating a Routing and Material Assignment

Solution 14: Material Assignment and Component Allocation Task 1: Display the material assignment of your T-B## routing. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Display or use transaction code CA03.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

Select the Header icon

d)

Choose the Material Assignment icon

e)

In the dialog box that appears, you will see your material, T-B##, plant 1000, listed in the table as assigned to use this routing.

.

to go to the header details. .

b y

Task 2: Assign materials to your group routing.

i n t e r n a l

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Leave material blank, enter plant 1000, group PUMP##, and choose Enter .

c)

Select the Header icon

d)

Choose the Material Assignment icon

e)

In the dialog box that appears, enter Group counter 1, material T-F1##, and plant 1000 on the first line in the table.

f)

Enter Group counter 1, material T-F2##, and plant 1000 on the second line in the table.

g)

Choose Continue

h)

Choose Save

to go to the header details.

o n l y

.

and both materials are assigned to use this routing.

to save your routing and exit.

Continued on next page

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© 2006 SAP AG. All rights reserved.

C S C

a)

b y

F o r

Assign the materials T-F1## and T-F2## to your group routing PUMP##.

u s e

u s e

1.

i n t e r n a l

C S C

Display the material assignment for your T-B## routing.

F o r

o n l y

1.

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Unit 6: Task Lists

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Task 3: Assign material components from the BOM to specific operations on the routing. 1.

First, create a plant-specific BOM for T-B## in plant 1000. Use the BOM T-B1## as a template. a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create.

Material

T-B##

Plant

1000

Usage

1

Valid from

Today's date

c)

In the Copy From.. dialog box, enter the material T-B1##, plant 1000, and BOM Usage 1 and choose Enter .

d)

Select all of the components to copy and choose Copy

e)

Save the BOM by choosing

u s e

Select the Copy from icon

.

Assign material components from the BOM of T-B## to specific operations on the routing. Assign components T-T2## and T-T3## to operation 30. Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

Select the Component Allocation icon .

d)

Select items T-T2## and T-T3## from the BOM that appears. Choose the New Assignment icon

.

.

e)

You can enter operation 30 in the activity field or choose to select the operation from a list.

f)

Choose Continue

g)

Choose Save

.

to save your routing and exit.

Continued on next page

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o n l y

a)

C S C

F o r

again.

b y

i n t e r n a l

2.

.

u s e

b)

i n t e r n a l

C S C

Entry

b y

Field

F o r

o n l y

Enter the data from the table below.

PLM114

Lesson: Creating a Routing and Material Assignment

Task 4: Assign components to specific operations on your group routing. Assign the material components from T-F1## to specific operations on your group routing PUMP##. Assign components T-B1## and T-T3## to operation 40, and T-B2##, T-B3##, and T-B4## to operation 20 of your group routing PUMP##.

Choose the Component Allocation icon . A dialog box appears showing a list of all materials that are assigned to that routing. Choose T-F1## by clicking on the line in the table and choose . Select items T-B1## and T-T3## from the BOM that appears. Choose

f) g)

Choose Continue and repeat steps e through f to assign components T-B2##, T-B3##, and T-B4## to operation 20.

h)

Choose Save

i)

If you want, you can repeat the above procedure to make component assignment for the T-F2## BOM to your PUMP## group routing.

the New Assignment icon

.

You can enter operation 40 in the activity field, or choose

i n t e r n a l

to select the operation from a list.

to save your routing and exit.

C S C

e)

b y

d)

u s e

o n l y

c)

C S C

Leave material blank, enter plant 1000, group PUMP##, and choose Enter .

b y

b)

i n t e r n a l

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

F o r

a)

u s e

1.

F o r

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Lesson Summary You should now be able to: • Assign manufactured items to routings • Allocate material components to operations • Maintain cutting measures of variable-size items

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

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PLM114

Lesson: Suboperations and User-Defined Fields

Lesson: Suboperations and User-Defined Fields Lesson Overview In this lesson, you will learn how to use suboperations for more detailed planning and how user-defined fields can be used to add information to the routing and order.

Lesson Objectives After completing this lesson, you will be able to: Describe the functions of suboperations Retrieve additional fields in operations

F o r

o n l y

• •

Business Example

307

C S C

b y

u s e

i n t e r n a l

F o r

o n l y

© 2006 SAP AG. All rights reserved.

C S C

2006/Q2

b y

Suboperations are subordinate to an operation and used for more detailed planning of the process step that is described in the operation. They are typically used to carry out more detailed planning for capacity or costing for an operation. For example, you can use suboperations to assign several people or machines that are required at the same time, to an operation. A suboperation can be costed, but can only be scheduled relative to the superior operation. You can cumulate standard values from suboperations on the corresponding operation. You can determine whether suboperations belonging to an operation are copied into the production order.

u s e

Suboperations

i n t e r n a l

As a production planner, you are responsible for routing management in the project team. You would like to model more detailed capacity constraints in your manufacturing process. You have several materials that require the use of specific tools during production. You would like to use suboperations to model these material specific constraints. You also need to use user-defined fields for transferring data in the operation from other systems.

PLM114

F o r

o n l y

Unit 6: Task Lists

C S C

C S C

i n t e r n a l

b y

The control key has an important influence on this process. When using suboperations, it is important that you ensure costs and capacity requirements are not calculated twice.

u s e

u s e

In the figure, operation 20 is responsible for compliance with the production schedule. suboperations 20/10 to 20/40 are used for exact capacity planning and costing.

i n t e r n a l

Suboperations are hierarchically structured under an operation and are used to carry out more detailed capacity planning or costing. For example, suboperations are used in a company at manufacturing centers.

b y

Figure 122: Suboperations

F o r

o n l y

Figure 123: Scheduling Suboperations

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PLM114

Lesson: Suboperations and User-Defined Fields

The dates of the suboperations are determined using the start or finish reference for an operation when you specify an offset value. The reference dates for the start and finish of a suboperation are: • • • • • •

Start date for setup Start date for processing Start date for teardown Finish date for execution Start date for wait time Finish date for wait time

b y

o n l y

C S C

b y

u s e

User Defined fields in the Routing

F o r

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o n l y

You can use user-defined fields to assign data fields to an operation or suboperation. You define the usage and meaning of these data fields yourself. You can enter business information or values for formula parameters that are not included in the standard system.

C S C

i n t e r n a l

You cannot assign material components, production resources/tools nor inspection characteristics to suboperations, only to operations.

u s e

An operation that is not to be carried out in the plant in the operation or routing can be assigned to another plant. The plants only have to belong to the same controlling area. A suboperation can be assigned to another plant as its superior operation. The unit of measure in the suboperation can differ from the one in the operation.

i n t e r n a l

Example: If you set a start reference for a suboperation to start processing with a time offset of 5- (5 minus) hours, processing in the suboperation will start 5 hours before it does in the main operation.

F o r

If an operation is divided into suboperations, the standard values for the suboperations can be cumulated under the main operation. If the suboperations run in parallel, this kind of cumulation is not possible because the cumulated values would be too high.

PLM114

F o r

o n l y

Unit 6: Task Lists

Figure 124: User-Defined Fields

C S C

b y

•

i n t e r n a l

F o r

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o n l y

A field key is defined in Customizing for routings, in which the required combination of user-defined fields is stored. By assigning a field key to an operation or suboperation, you determine which user-defined fields are available in the particular object and also which field names or key words are used for these fields You can then enter data in these user-defined fields. Note that the system does not check for data validity.

C S C

• •

b y

•

u s e

u s e

•

Up to four general fields for any text You can use them to store information about people responsible, substitutes or telephone numbers, for example. Up to two quantity fields You can assign additional formula parameters to the quantity fields in the field key. With the help of formula parameters you can use the values of the quantity fields in work center formulas, to calculate processing times, capacity requirements and costs. In addition, there is also a field for the unit of each quantity field. Default values and their units which you have maintained in Customizing for formula parameters are transferred, but you can change this data. If you have entered data in the quantity fields and then change the field key, the old values remain unchanged. Up to two value fields – In addition there is also a field for the unit of each value field. Up to two date fields – Here you can enter internal start dates, for instance. Up to two check boxes – You can use these to indicate whether an operation is to be included in evaluations in the Info System, for instance.

i n t e r n a l

Depending on the field key, up to twelve data fields with various field formats are available. These are:

PLM114

Lesson: Suboperations and User-Defined Fields

Exercise 15: Suboperations for Material-Specific Capacity Constraints Exercise Objectives After completing this exercise, you will be able to: • Model detailed capacity planning for an operation using suboperations • Create suboperations • Accumulate the standard values of the suboperations in the superior operation

Business Example

o n l y

C S C

Use suboperations to model more detailed planning of operation steps.

u s e

Ref Date to Start

Offset to start

10

Setup

3 Min

0 Min

0 Min

01

0 Min

20

Mill Pump casing

0 Min

15 Min

15 Min

02

0 Min

30

Turn pump casing 0 Min

10 Min

10 Min

02

15 Min

40

Deburr pump casing

10 Min

10 Min

02

25 Min

0 Min

Task 2: Accumulate the standard values of the suboperations in the superior operation.

2006/Q2

1.

In your routing for T-B##, first check the standard values in the superior operation 20.

2.

In your routing for T-B##, accumulate the standard values of the sub-operations in the superior operation 20.

© 2006 SAP AG. All rights reserved.

311

o n l y

Labor

C S C

Setup Machine

b y

Description

u s e

Subop

i n t e r n a l

In the production of T-B##, operation 20 has several steps that must be capacity planned in more detail. Create four suboperations to model the detail capacity of this operation using the data in the table below.

F o r

b y

1.

i n t e r n a l

Task 1:

F o r

One of the operations in your production process consists of several steps that need to be planned in more detail for capacity. You want to use suboperations to do this.

Unit 6: Task Lists

PLM114

Solution 15: Suboperations for Material-Specific Capacity Constraints Task 1: Use suboperations to model more detailed planning of operation steps.

Labor

Ref Date to Start

Offset to start

10

Setup

3 Min

0 Min

0 Min

01

0 Min

20

Mill Pump casing

0 Min

15 Min

15 Min

02

0 Min

30

Turn pump casing 0 Min

10 Min

10 Min

02

15 Min

40

Deburr pump casing

10 Min

10 Min

02

25 Min

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

Overwrite operation number 0050 with 0020, then enter suboperation number 10, work center T-B##, and the description from the table above.

C S C

d)

Select the suboperation and choose Details → Operation to enter the standard values and offset information. You may have to scroll down in the details to enter the offset.

o n l y

i n t e r n a l

a)

e)

Repeat this procedure for each suboperation and save your routing.

.

Continued on next page

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b y

F o r

0 Min

u s e

u s e

o n l y

Setup Machine

i n t e r n a l

Description

F o r

Subop

C S C

In the production of T-B##, operation 20 has several steps that must be capacity planned in more detail. Create four suboperations to model the detail capacity of this operation using the data in the table below.

b y

1.

PLM114

Lesson: Suboperations and User-Defined Fields

Task 2: Accumulate the standard values of the suboperations in the superior operation. 1.

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b y

b)

Enter material T-B##, plant 1000, and choose Enter .

c)

To check the standard values of the superior operation 20, select the operation and choose Details → Operation. Make note of the values for Setup, Machine, and Labor.

In your routing for T-B##, accumulate the standard values of the sub-operations in the superior operation 20. Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

In the operation overview, select the superior operation 20.

d)

Choose Extras → Summarize standard values.

e)

Now check the standard values of the superior operation 20 to see if they have been updated. Select operation 20 and choose Details → Operation. You will see that the standard values have been updated from the accumulated totals of the suboperations.

.

b y

a)

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Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

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a)

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In your routing for T-B##, first check the standard values in the superior operation 20.

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Lesson Summary You should now be able to: • Describe the functions of suboperations • Retrieve additional fields in operations

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Lesson: Reporting and Mass Changes

Lesson: Reporting and Mass Changes Lesson Overview In this lesson you will learn the reporting options for routings and how mass changes can be accomplished.

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

Demonstrate how to make changes with history Demonstrate how to use where-used lists and mass changes

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Change with a Change Master Record

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Changes with history Changes with history must be documented because they take place during production. Both the status before and after the change is saved. The system creates change documents. For some objects, these change documents differ from those created for changes without history. Engineering change management in the SAP system enables you to fully document changes. Some of these changes may be needed for product liability purposes, for example.

u s e

Changes without history Changes without history do not have to be documented because they take place during the development stage of the product, for example. The status of the object prior to the change is not saved. The system documents the changes that have taken place but you can only find out indirectly about the status of the object before the change.

i n t e r n a l

In the project team, you are responsible for the where-used lists and the mass changes in routing management. Your company must document the changes in its routings. You are responsible for ensuring changes are documented with history.

F o r

Business Example

Unit 6: Task Lists

PLM114

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Engineering change management is a central logistics function that can be used to change various types of master data and document the changes.

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The changes take effect automatically at the predefined time in all areas of the logistics process chain, for example, sales order, material requirements planning and shop floor control.

b y

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You can use engineering change management to store certain SAP objects (for example, BOMs and routings) more than once. This means that you can store the objects in all relevant change statuses.

u s e

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By using a valid-from date for the change master record, the changes become valid on a predefined date. This aids long-term planning.

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Figure 125: Engineering Change Management

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Lesson: Reporting and Mass Changes

b y

u s e

As of release 4.0, there are other types of parameter effectivity besides date, for example, serial number, time interval, customer. These topics are discussed in more detail in the PLM150 – Engineering Change Management course.

b y

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You can make object changes (for example: BOM and routing changes) in the SAP system either with or without history. However, you should be aware that change documents are created by the system even for changes without history.

Reporting and Mass Changes

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You can use the overview variant to control the information in the list and the order in which it is listed (for example, sequence, operation, component, PRT). You can create various displays for routings using object overviews. You can define your own object overviews in configuration in the IMG.

C S C

You can use engineering change management to help fulfill your legal obligations regarding documentation of changes.

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You can use engineering change management to group together changes to different SAP objects that are affected by one change. You can change all the objects at the same time or you can define different change dates for individual objects.

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Figure 126: Why Use Engineering Change Management?

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Figure 127: Reporting Variants

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By generating where-used lists, you can display the routings which use particular work centers, reference operation sets, reference rate routings, and production resources/tools (PRTs). You may need this information if you want to delete a work center or reference operation set but you want to first check if it is being used in a routing. If you want, you can also display routings which have already been deleted online but which still exist in the database.

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Figure 128: Where-Used Lists

Where-used lists can be generated for work centers, capacities, production resources/tools, and reference operation sets.

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Lesson: Reporting and Mass Changes

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b y

You can use the Replace function to make mass changes to the following:

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Work centers PRTs Reference operation sets

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• • •

The system generates a list of all routings that use the object to be replaced. When you use the mass replace function without a change number, the new objects will have the same validity periods as the old objects.

b y

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If you want to replace an object in several routings with another object (for example, an old work center with a new one) you can use the mass replace function. You do not have to generate a where-used list in order to replace each work center individually. Instead, you can use the mass replace function to quickly and completely replace work centers in all routings where they are used.

F o r

Figure 129: Mass Change and Reporting

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Figure 130: Mass Replacement of Routing Data

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You can use the replace function to make mass changes to work centers, PRTs, and reference operation sets.

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Lesson: Reporting and Mass Changes

Exercise 16: Task List Changes with ECM Exercise Objectives After completing this exercise, you will be able to: • Make changes without history in a task list • Make changes with history in a task list • Display changes with history in a task list • Make mass changes with history in a task list

Business Example

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Determine to which other task lists work center T-B## has been assigned by executing a work center where-used list.

Task 3:

F o r

1.

Replace the final assembly work center T-C## on your T-B## routing, with your new work center CENTER## using your Engineering Change Number ECN## to track history.

Continued on next page

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Because of a capacity constraint in your production, your company is building a new work center that will be operational in two months. Replace the final assembly work center in your routing effective on that day and be sure to track history.

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1.

Check to see which routings and rate routings are using a specific work center.

b y

Task 2:

Display a list of changes that have been made to your routing, T-B##, thus far.

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1.

Display a list of all changes without history that have been made to your routing.

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Task 1:

F o r

As new work centers are created to update your production equipment, task lists will also need to be updated. This may require changes to be captured with history for legal or reporting purposes. These changes also may need to be made in mass for all routings.

Unit 6: Task Lists

PLM114

Task 4: Display your routing with different key dates to view the change history. 1.

Display your routing with a key date one day before the change date (today + 2 months - 1 day). Which work center is assigned to operation 40? What are the validity dates of operation 40?

2.

Display your routing using a key date of one day after the change date (today + 2 months + 1 day). Which work center is assigned to operation 40? What are the validity dates of operation 40?

Task 5:

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Your new work center, CENTER## , will replace work center T-F## on all routings two months from today. Use mass replace and change number ECN## to track history.

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1.

F o r

Since the new work center will replace the old one on all routings, do a mass replace with history.

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Lesson: Reporting and Mass Changes

Solution 16: Task List Changes with ECM Task 1: Display a list of all changes without history that have been made to your routing. Display a list of changes that have been made to your routing, T-B##, thus far.

b)

Enter task list type N, material T-B##, and plant 1000. Accept the default dates, be sure that all changes in the list are selected, and choose Execute .

c)

This is the list of changes that have been made to your routing. Look at the Changed on date and Changed by field.

Task 2: 1.

Check to see which routings and rate routings are using a specific work center.

u s e

Choose an overview variant from the list that displays work centers like L00000000060 and choose Enter. The system displays a list of all routings and rate routings that have the work center assigned, as well as the sequence and operation to which it is assigned.

F o r

c)

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Enter the work center T-B## and plant 1000. Accept the default key date, enter task list type N in the from field, S in the to field to check all routings and rate routings, and choose Execute .

C S C

b)

b y

Choose Logistics → Production → Master Data → Routings → Routings → Reporting → Where-Used List → Work Center or use transaction code CA80.

u s e

a)

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Determine to which other task lists work center T-B## has been assigned by executing a work center where-used list.

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C S C

Choose Logistics → Production → Master Data → Routings → Routings → Reporting → Task List Changes or use transaction code CA60.

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a)

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Task 3: Because of a capacity constraint in your production, your company is building a new work center that will be operational in two months. Replace the final assembly work center in your routing effective on that day and be sure to track history.

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings→ Change or use transaction code CA02.

b)

Enter the material T-B##, plant 1000, change number ECN##, and choose Enter .

c)

A warning message appears in the status bar indicating, “The key date is overwritten with the date from the change number record.” Press ENTER to work through the warning.

d)

In operation 40, replace work center T-C## with CENTER## and save your routing.

b y

Task 4:

i n t e r n a l

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings→ Display or use transaction code CA03.

b)

Enter the material T-B##, plant 1000, key date one day before the change date (today + 2 months - 1 day), and choose Enter .

c)

The work center assigned to operation 40 is T-C##.

d)

Double-click on the operation number and scroll to the bottom of the operation details screen to see the validity dates. The Valid To date should be the change date used in the change number or two months from today.

Continued on next page

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o n l y

F o r

a)

C S C

Display your routing with a key date one day before the change date (today + 2 months - 1 day). Which work center is assigned to operation 40? What are the validity dates of operation 40?

b y

1.

u s e

u s e

Display your routing with different key dates to view the change history.

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C S C

Replace the final assembly work center T-C## on your T-B## routing, with your new work center CENTER## using your Engineering Change Number ECN## to track history.

F o r

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1.

PLM114

Lesson: Reporting and Mass Changes

Display your routing using a key date of one day after the change date (today + 2 months + 1 day). Which work center is assigned to operation 40? What are the validity dates of operation 40? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings→ Display or use transaction code CA03.

b)

Enter the material T-B##, plant 1000, key date one day before the change date (today + 2 months - 1 day), and choose Enter .

c)

The work center assigned to operation 40 is CENTER##.

d)

Double-click on the operation number and scroll to the bottom of the operation details screen to see the validity dates. The Valid From date should be the change date used in the change number or two months from today.

C S C

Since the new work center will replace the old one on all routings, do a mass replace with history.

c)

On the list, select the operations for which you want to replace the work center and choose Replace work center .

d)

Check the routings you just changed to see the change and the validity date.

F o r

Enter the work center T-F##, plant 1000, new work center CENTER##, plant 1000, change number ECN##, and choose Execute .

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b)

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Choose Logistics → Production → Master Data → Routings → Extras → Mass Changes→ Replace Work Center or use transaction code CA85.

b y

a)

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u s e

Your new work center, CENTER## , will replace work center T-F## on all routings two months from today. Use mass replace and change number ECN## to track history.

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b y

1.

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Task 5:

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2.

Unit 6: Task Lists

PLM114

Lesson Summary You should now be able to: • Demonstrate how to make changes with history • Demonstrate how to use where-used lists and mass changes

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Lesson: Configuring the Routing

Lesson: Configuring the Routing Lesson Overview In this lesson you will learn about the customizing settings that controll the routing at the header level and also the item level.

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

Define system settings for routings

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In this step, you define number ranges for groups of routings, reference operation sets, rate routings, and reference rate routings. To create a these objects, SAP R/3 requires a unique group number. You can create any of these objects with or without a group. If you do not enter a group number, the system assigns one to the task list. The internal group number is within the number range you define in this step. You can also define number ranges for external assignment of group numbers.

i n t e r n a l

Configuring Routings: Control Data

F o r

In the project team, you are responsible for routing administration. You need to be aware of what options your company can take advantage of to adapt their existing routings to SAP ERP.

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Business Example

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F o r

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Figure 131: Routing Configuration: Control Data

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In the next step, you assign number ranges you defined in the previous step to the respective task list types. Both internal and external number ranges are assigned here. Here you can also activate the following options for each task list type: • •

Write change documents Last maintained value for the material (and plant of the material), task list group, and sales document will default in task list maintenance Last maintained refers to the last entry of a specific user, and not the last entry in the system. If you would like to access fixed-user values instead of the last maintained value, do not activate this option. Also select SET parameters and GET parameters in the field attributes of the respective field, such as the Material field. Entering a fixed value in the user parameters alone is not sufficient.

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Authorization check for deletion active.

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b y

•

Check material type against components

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Define material type assignment: In this activity, you can define for each material type which task list types can be used to create routings.

C S C

Configuring Routings: General Data

b y

In this step you specify the line lengths of the various texts in routing long texts. The length of the short text on the corresponding overview and detail screens is always limited to 40 characters. If the long text has more than 40 characters, the short text will display only the first 40 characters. This table setting affects the long texts of the following objects: header, sequence, operation, suboperation, and PRT assignment.

u s e

In this step, you maintain column headings for standard values on the operation overview. If all work centers where operations are processed use the same descriptions in the standard value key, the system dynamically determines a common description for the standard value column heading. If no common header can be determined for a column of standard values, the system sets the description from the Customizing table according to task list type. The same procedure applies when a sequence or a task list is created for the operation overview.

i n t e r n a l

You use this indicator to specify that a user requires deletion authority for the relevant task list to delete a task list, change the deletion flag for a task list, delete a sequence of a task list, or delete an operation or phase of a task list. If you do not set this indicator, the user only needs change authority to carry out these activities for the relevant task list type.

F o r

•

PLM114

Lesson: Configuring the Routing

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F o r

C S C

Define routing status: The status defines: Whether a reference operation set can be used in routings (Released indicator) Whether the routing is released for costing Whether a consistency check is run before saving (for details of the scope of the consistency check, see the online help)

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•

F o r

Configure planner group: Check table - selection criterion Overview variants: Overview variants can be defined for object overviews, where-used lists, and scheduling. These are not relevant to the engineering workbench environment.

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•

Automatic selection ID (as priority list regarding routing category, usage, and status) or User selection (ABAP routine)

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The task list usage is used for:

b y

Define task list usage: You can use task list usages to create different task lists for a material and plant, and use routing selection to control selection. The only parameter that can be assigned to the usage here is the dynamic modification criterion, which is relevant to quality management only.

u s e

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b y

• • •

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Figure 132: Routing Configuration: General Data

Unit 6: Task Lists

PLM114

Profiles with Default Values In this step, you define task list profiles. A profile is a collection of default values for task list headers and operations. You can minimize the maintenance of task list data as follows: •

Data from the material master is proposed.

• •

Data from the work center can be referenced or copied Data from the profile is proposed.

o n l y

F o r

Use the following procedure:

2. 3. 4.

330

Determine the default values that can reduce the amount of maintenance work in your company. If necessary, define several profiles. Maintain the default values for routing maintenance. Maintain the default values for quality assurance.

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o n l y

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You can enter a profile in routing maintenance. The values from this profile are proposed when you create a new routing or routing object, such as a header or an operation. This data can either be saved or overwritten.

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Figure 133: Default Values Profiles

PLM114

Lesson: Configuring the Routing

In this step, you can select fields for the following screens: • • • • •

Task list header screens Sequence screens Operation screens PRT overview PRT details

All of the screens where field selection is possible are combined into individual screen groups. For each screen group, you define the modifiable and influencing fields. For modifiable fields, you use an indicator to determine how the individual fields are displayed on the screen:

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User-Defined Fields in Operations

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User-defined field keys are used to add data entry fields for user data to the operation detail screen. These field keys can offer the following fields:

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Quantity

Field type

2

Text (20 characters)

2

Text (10 characters)

2

Date

© 2006 SAP AG. All rights reserved.

b y

The field selection settings you define can be transported and will remain unchanged when you upgrade to a new release. If a modifiable field becomes a required entry because of a change to an influencing field, the system does not check whether this field is filled with objects that already exist. You cannot modify required fields that are already hard-coded for the application.

u s e

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b y

If you determine for the list and detail screens for confirmation within the network that work center is a required entry, you must maintain the work center in all confirmations. For the influencing fields, you determine how the modifiable field is displayed on the screen, depending on a value (for example, work center is a required entry for a certain order type).

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Field is ready for input (standard setting) Field requires an entry (required entry) Field is display only Field is hidden Field is highlighted

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• • • • •

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2

Quantity and unit of measure (can also be used by assignment to a parameter of origin 4 in formulas)

2

Value and/or currency

2

Checkboxes

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The quantity fields can be used as formula parameters in formulas for calculating execution time and capacity requirements. These fields can also be used in product costing.

C S C

In Customizing, the user first creates a field key name, then enters the field name for each additional field.

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Figure 134: User-Defined Fields

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Lesson: Configuring the Routing

Lesson Summary You should now be able to: • Define system settings for routings

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Unit Summary

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Unit Summary

o n l y

F o r

You should now be able to: • Describe the different types of task lists • Describe the integration points of the task list • Assign manufactured items to routings • Allocate material components to operations • Maintain cutting measures of variable-size items • Describe the functions of suboperations • Retrieve additional fields in operations • Demonstrate how to make changes with history • Demonstrate how to use where-used lists and mass changes • Define system settings for routings

b y

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Test Your Knowledge

Test Your Knowledge 1.

Which of the following is not a way to create routing material assignments in SAP ERP? Choose the correct answer(s).

2.

□ □

A B

□ □

C D

Create a material specific routing Copy a materials master record and the BOM and routing are automatically copied also In the routing header create a material assignment Create a production version

Which of the following is not a pre-requisite for component allocation?

o n l y

C S C

b y

3.

A B C D

Operations in the routing must exist Production version must exist BOM for the material to be produced must exist Backflush indicator must be set

Any materials component that is not assigned to an operation in the routing will default to the first operation.

Each item on the BOM can be assigned to one and only one operation on the routing. Determine whether this statement is true or false.

C S C

4.

True False

Component allocation to an operation is the only additional information which can be maintained with regard to components. Determine whether this statement is true or false.

□ □ 6.

True False

Suboperations can be used for more detailed capacity planning and costing. Determine whether this statement is true or false.

□ □

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□ □ 5.

True False

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□ □

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Determine whether this statement is true or false.

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□ □ □ □

F o r

Choose the correct answer(s).

Test Your Knowledge

7.

PLM114

When using suboperations costing is automatically done at the operation level regardless of the control keys. Determine whether this statement is true or false.

□ □ 8.

True False

You can use user-defined fields to assign data fields to an operation or suboperation for information purposes only. Determine whether this statement is true or false.

9.

True False

Which of the following are ways to make changes to routings in SAP ERP? Choose the correct answer(s).

C S C

b y

A B C D

Without record of changes With change documents With history using ECM All of the above

u s e

Determine whether this statement is true or false.

11. It is not possible to make mass changes to routings using an ECM number. Determine whether this statement is true or false.

True False

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True False

b y

□ □

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10. A where-used list can show you which task lists will be affected by a change in work center.

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Test Your Knowledge

Answers 1.

Which of the following is not a way to create routing material assignments in SAP ERP? Answer: B There are 3 ways to create material assignments in the routing; create a material specific routing, create a material assignment in the header of the routing, create a production version. Material master records that are copied do not copy the BOM and routing also. Which of the following is not a pre-requisite for component allocation? Answer: B, D

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b y

3.

Any materials component that is not assigned to an operation in the routing will default to the first operation.

4.

Answer: True

F o r

5.

Component allocation to an operation is the only additional information which can be maintained with regard to components. Answer: False According to the item category of the assigned components you can make further decisions about their processing, like backflushing of stock items or cutting size of variable-size items.

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o n l y

Each item on the BOM can be assigned to only one operation. Items which have quantities of more than one and need to be assigned to more than one operation will need to be adjusted in the BOM to allow this type of allocation.

C S C

Each item on the BOM can be assigned to one and only one operation on the routing.

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Material components in a BOM that are not assigned to an operation in the routing are automatically assigned (default) to the first operation when you create a production order.

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Answer: True

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Before you can allocate components to specific operations on the routing the operations must exist in the routing and the BOM must exist for the material to be produced.

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Test Your Knowledge

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Suboperations can be used for more detailed capacity planning and costing. Answer: True Suboperations are subordinate to an operation and used for more detailed planning of the process step that is described in the operation. They are typically used to carry out more detailed planning for capacity or costing.

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When using suboperations costing is automatically done at the operation level regardless of the control keys. Answer: False

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You can use user-defined fields to assign data fields to an operation or suboperation for information purposes only. Answer: False

Which of the following are ways to make changes to routings in SAP ERP?

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Answer: D Changes to routing can be made without history, with changes documents, or with history using ECM.

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Answer: True A where-used list can show you which task lists contain a specific work center and will be affected by a changed in that work center. 11. It is not possible to make mass changes to routings using an ECM number. Answer: False You can make changes to routings using mass change and by using an engineering change number.

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10. A where-used list can show you which task lists will be affected by a change in work center.

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You can use user-defined fields to assign data fields to an operation or suboperation. You can enter business information or values for formulas parameters that are not included in the standard system. The values for formula parameters could be used for calculating capacity requirements, scheduling, or costing.

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When using suboperations, it is important that you ensure costs and capacity requirements are not calculated twice by using the appropriate control keys.

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Unit 7 Advanced Bill of Material Functions Unit Overview

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• • • • • • • • • • • •

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Unit Objectives

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Explain the concept of a phantom BOM and when it should be used Create a phantom BOM in SAP R/3 Maintain phantom bills of material Demonstrate model co-products and by-products Demonstrate and explain the discontinuation process. Model item substitutions in the bill of material Discuss the advantages of using multiple and variant BOMs Create a multiple BOM Create a variant BOM Define variant configuration Update BOMs using mass changes Navigate the product structure browser

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After completing this unit, you will be able to:

Unit Contents Lesson: Phantom Assemblies.................................................341 Lesson: Co-Products and By-Products ......................................345 Exercise 17: Co-Products in Production Orders .......................349 Lesson: Discontinuation and Substitute Parts in the Bill of Material .....353 Exercise 18: Substitute Items in Production Orders ...................359 Lesson: Multiple and Variant BOMS..........................................369 Exercise 19: Multiple/Alternative Bills of Material ......................377 Exercise 20: Variant BOMs ...............................................387

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This unit introduces several advanced concepts surrounding the bill of material in SAP ERP. Not all of the following functions will be required to use during the modeling of your company's manufacturing process. These functions will include the user of multiple bills of materials, co-products/by-products, substitute parts and other miscellaneous functions.

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Lesson: Mass Changes and the Product Structure Browser..............393 Exercise 21: Mass Changes and the Product Structure Browser....397

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Lesson: Phantom Assemblies

Lesson: Phantom Assemblies Lesson Overview During the design or manufacturing of a product, engineering often times creates “phantom” or “dummy” assemblies. The purpose of these assemblies is to make maintenance of the item easier as the product evolves and changes.

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

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Explain the concept of a phantom BOM and when it should be used Create a phantom BOM in SAP R/3 Maintain phantom bills of material

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As a production planned, you have some parts that are categorized as service parts. These items are used in production, but are also sold directly to customers as the items' wear and tear requires them to be replaced. You would like the item used in production to be classified as a phantom bill of material.

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For example, the phantom assembly “set of wheels” contains the components “front wheel” and “rear wheel.” The front and rear wheels are placed immediately into the “bicycle” assembly. The “light” assembly contains the materials “bulb” and “reflector.” The light components are first assembled and then the light is attached to the bicycle.

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A phantom assembly is a logical grouping of materials. A phantom assembly is usually created within engineering to describe a number of components easily and manage them as a whole. The components in a phantom assembly are placed immediately into the superior assembly. As opposed to this, components in an assembly are first assembled to produce the header material. After this, the header material is placed into the superior assembly.

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Phantom Assemblies

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Phantom assemblies also facilitate component assignment, since the components of a phantom assembly are assigned to the same operation. The same is true for the phantom assembly itself if you have not made an assignment for the components. During the BOM explosion in an SAP R/3 production order, the BOMs for phantom assemblies are also exploded. The components of the phantom assemblies become normal reservations, while the phantom assembly itself is transferred to the order as an unplanned effective reservation. The components of a phantom assembly are connected in a hierarchy with the superordinate assembly.

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Phantom assemblies are used in SAP R/3 to enable the simple structuring of BOMs; the items typically do not physically exist. You can see phantom assemblies as parentheses around a group of components that are often used in conjunction with each other. This significantly reduces the amount of administration needed for the master data. For changes to materials (for example, discontinued material) you only have to carry out the changes on one BOM. The changes have an effect on all BOMs used by the phantom assemblies.

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Figure 135: Phantom Assemblies

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Lesson: Phantom Assemblies

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In addition, there are two settings that can be set in the bill of material for a component. In the details of the component, under the MRP section, users can use the explosion type or special procurement. The explosion type can switch the phantom assembly off for this BOM, and it will create a planned order for the item. This overrides the material master setting. Setting the special procurement key in the BOM to phantom assembly means that when this item is used in a the relevant BOM, it will be treated as a phantom. The settings in the BOM have priority over the material master since they are specific to a usage or manufacturing process.

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The settings for phantoms can occur in three different places in SAP R/3. The highest level to determine a part as a phantom assembly is at the material master. In the MRP 2 view, users can set an item to be a phantom assembly by setting the special procurement key. This means that this part at the plant level will not be manufactured and inventoried in that form.

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Figure 136: Setting Phantoms in SAP R/3

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Lesson Summary You should now be able to: • Explain the concept of a phantom BOM and when it should be used • Create a phantom BOM in SAP R/3 • Maintain phantom bills of material

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Lesson: Co-Products and By-Products

Lesson: Co-Products and By-Products Lesson Overview To model the manufacturing of multiple co-products, companies must consider the list of all BOM components that are necessary to effectively manage the yields and competing resources.

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

Demonstrate model co-products and by-products

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A co-product is a material that is manufactured simultaneously with the main product. In certain cases, the main material cannot be manufactured in isolation, without also producing the co-product, for a given production process.

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Co-Products in Manufacturing

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During the machining of the casing for your pump, brass shavings are produced. These brass shavings are then sold back to the refiner who sold your company the brass ingot that was used in forging the casing. As a production planner your costing accounting group has asked you to model the brass shavings as a co-product in order to get the proper credit to manufacturing for the sale of the brass shavings. In addition to the brass, oil is used to cool the cutting blades during the machining process. The oil is collected and inventoried for proper disposal. This process is regulated by the government and has not value. Model the oil used for each casing as a by-product.

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Use in ECC PP-PI Module: The process industry is full of numerous examples, where due to the nature of the chemical and biological reactions, there is a concurrent yield for multiple products. Typically there is one main product being manufactured. The rest of the products could be categorized as co-products, by-products, waste products. Co-products and by-products have a non-zero inventory valuation, as opposed to waste products having a zero unit cost. Furthermore, since the co-products label is given to products that have a higher cost visibility, then any other generic by-product in your company, the co-products are also earmarked for cost settlement at the end of the process order life cycle.

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Figure 137: Manufacture of Co-Products

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Figure 138: Co-Products in the BOM

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Lesson: Co-Products and By-Products

Main Leading Material and Co-Product - Structure: Co-products, by-products, and waste products are set up as a negative quantity components in the BOM of the Master Recipe. Since co-products have further cost settlements, a series of indicators have to be setup in the product masters and the BOM. All of the product masters, and the negative quantity components must have the co-product indicator fields check marked. Also the cost apportionment ratios for all of the cost components that are involved with the co-products, have to be defined in their product masters. To better understand Co-products we first must understand several related terms. All of these terms are used frequently in the Food, Chemicals, Electronics, and other process, repetitive and flow manufacturing industries.

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Waste product In ECC a waste product is a material that is manufactured simultaneously with the main product. The main material cannot be manufactured in isolation, without also producing the waste product, for a given production process. Waste products have a zero inventory valuation. Waste products are not earmarked for cost settlement at the end of the process order life cycle, and just like by-products, do not appear in the header settlement rule.

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By-product In ECC a by-product is a material that is manufactured simultaneously with the main product. The main material cannot be manufactured in isolation, without also producing the by-product, for a given production process. By-products have a non-zero inventory valuation. By-products are not earmarked for cost settlement at the end of the process order life cycle, and do not appear in the header settlement rule.

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Co-product In ECC a co-product is a material that is manufactured simultaneously with the main product. The main material cannot be manufactured in isolation, without also producing the co-product, for a given production process. Co-products have a non-zero inventory valuation. Co-products are also earmarked for cost settlement at the end of the process order life cycle, and appear in the header settlement rule.

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Lesson: Co-Products and By-Products

Exercise 17: Co-Products in Production Orders Exercise Objectives After completing this exercise, you will be able to: • Explain how to set up co-products in SAP ERP

Business Example

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The stamping and assembly operations of the pump yields two additional gaskets which are not needed for the pump, but they have value. You need to put them into inventory.

Task 1: Define co-products on the BOM

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Define material T-G##, plant 1000 as a co-product on the BOM of pump T-F1##.

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Task 2: Optional: Test the co-product setting

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Create a production order for T-F1##. View the co-product results in the stock requirements list.

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Solution 17: Co-Products in Production Orders Task 1: Define co-products on the BOM Define material T-G##, plant 1000 as a co-product on the BOM of pump T-F1##. a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change.

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Enter the following data from the table below.

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Plant

1000

BOM Usage

1

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Choose Enter

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Enter the following in the first available component item on the General Item Overview screen.

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T-F1##

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Field

Entry

Component

T-G##

Quantity

2-

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Choose Enter

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Go to the item details by double-clicking the item number or highlighting the line and selecting the item icon (or pressing F7).

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On the Basic Data tab, select the Co-product indicator.

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Save the BOM.

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Task 2: Optional: Test the co-product setting Create a production order for T-F1##. View the co-product results in the stock requirements list. a)

Choose Logistics → Production → Production Control → Order → Create → With Material (CO01).

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Enter the following data and press ENTER. Entry

Material

T-F1##

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1000

Order Type

PP01

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Total Qty

10

Finish

Current date + 1 month

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Enter the data from the table below.

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Entry

Material

T-G##

MRP Area



Plant

1000

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Choose Logistics → Production → MRP → Evaluations → Stock/Requirements List.

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Hint: If a message regarding costs is displayed; choose Yes to continue and save the order.

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Choose Enter

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A production order has been created for the co-product to be received into inventory. The quantity has been calculated based on the BOM quantity.

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Field

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Enter only the following two items and choose Save.

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Lesson Summary You should now be able to: • Demonstrate model co-products and by-products

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Lesson: Discontinuation and Substitute Parts in the Bill of Material

Lesson: Discontinuation and Substitute Parts in the Bill of Material Lesson Overview BOMs are seldom static. Component materials are replaced by other items. Certain components may also be substituted if the need arises. In this lesson, we will introduce discontinuation and alternative items as methods to manage such situations.

Lesson Objectives • •

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After completing this lesson, you will be able to: Demonstrate and explain the discontinuation process. Model item substitutions in the bill of material

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The engineering and 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 the following reasons:

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Discontinuation control works in the same way for long-term master production and requirements planning.

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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.

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In the manufacturing of several of your products, you use an extensive amount of wiring. The wiring is inventoried as several different part numbers, based on the grade of wire. In the event of an inventory shortage, engineering has authorized the use of higher grade wire in place of the standard item. As a production planner, you need to model this to assure that production orders can be completed when released to the shop floor. You want to model this substitution process in your bill of material.

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Figure 139: Discontinuation Control (Simple Discontinuation)

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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 is set. For information purposes, the follow-up material can be maintained in the BOM as a follow-up material.

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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.

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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.

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Lesson: Discontinuation and Substitute Parts in the Bill of Material

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Prerequisites:

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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. In the extras for the BOM item, 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 by which follow-up items the discontinued items are to be replaced. The character string of the succeeding group must correspond with the character string of the discontinued group.

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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. For example, a certain nut may be discontinued, meaning the corresponding screw is also discontinued.

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Figure 140: Discontinuation Control (Parallel Discontinuation)

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Alternative Items: Grouping

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Alternative items with specified usage probability

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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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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.

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This serves to summarize alternative items within an item list. All assembly materials can be entered into the alternative item group. As soon as you create an alternative item group, you will receive an additional dialog window containing the ranking order, strategy, and probability of usage. You can maintain alternative items for the following situations:

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Figure 141: Alternative Items

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Figure 142: Alternative Item Data Detail Screen

Backflush according to usage probability

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– Strategy (value 1 or no entry) – Ranking order (only affects the sorting of materials) – Usage probability Backflush at 100% availability

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For all items that are to be reserved, maintain the:

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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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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)

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Usage Probability

Ranking

Planned Requirement Amount

ATP Quantity:

Backflush quantity

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The first material in the ranking order that meets the requirement date 100% is reserved in the required quantity (material B). Once a partial backflush has occurred for a production order, no further check takes place for further partial flushes with this production order. Any future partial backflushes take place from the alternative item from which the first backflush occurred. 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.

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Lesson: Discontinuation and Substitute Parts in the Bill of Material

Exercise 18: Substitute Items in Production Orders Exercise Objectives After completing this exercise, you will be able to: • Enter alternative items on a BOM

Business Example Certain materials must be used as a substitute in case the standard material is not available.

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

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Use the requirements/stock list to display the current stock available for the following materials:

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T-B1## T-B2##

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T-B3## T-B4## T-T3##

T-B1##

100 pieces (exact)

T-B2##

200 pieces (minimum)

T-B3##

200 pieces (minimum)

T-B4##

200 pieces (minimum)

T-T3##

1800 pieces (minimum)

T-Z##

200 pieces (minimum)

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Change the stock for the above materials in plant 1000 at storage location 0001 to the following status:

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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, Priority 1, Strategy 2, and Usage probability 100. For item T-Z##, enter Alt.item group 01, Priority 2, Strategy 2, and Usage probability 1.

Task 2: Optional: Using a production order, test the effects of the alternative item(s). 1.

Test the effects of the alternative item group on production planning and material backflush.

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

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

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

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

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

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

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

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Repeat the last two steps to test the effect of the alternative item groups in the case of insufficient stock. 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 your data entries with ENTER, go to the Component overview to find the answers to the following questions:

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Exit and do not save the order.

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Carry out an availability check for all components.

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Caution: Do not save the order yet.

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

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Create a production order for the material T-F1## in plant 1000 for LESS 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 to find the answers to the following questions:

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Lesson: Discontinuation and Substitute Parts in the Bill of Material

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

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

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

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

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Caution: Do not save the order at this point. Carry out an availability check for all components. How high is the quantity requirement of T-B1##?

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

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

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

____________

i n t e r n a l

Do not save the order.

b y

i n t e r n a l

u s e

u s e

b y

C S C

F o r

o n l y

4.

C S C

F o r

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Solution 18: Substitute Items in Production Orders Task 1: Optional: Create alternative items in the BOM T-F1##. 1.

Use the requirements/stock list to display the current stock available for the following materials: T-B1## T-B2##

F o r

o n l y

T-B3## T-B4## T-T3##

100 pieces (exact)

T-B2##

200 pieces (minimum)

T-B3##

200 pieces (minimum)

C S C

b y

i n t e r n a l

T-B1##

u s e

u s e

b y

Change the stock for the above materials in plant 1000 at storage location 0001 to the following status:

i n t e r n a l

T-Z##

C S C

F o r

o n l y

Continued on next page

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Lesson: Discontinuation and Substitute Parts in the Bill of Material

T-B4##

200 pieces (minimum)

T-T3##

1800 pieces (minimum)

T-Z##

200 pieces (minimum)

a)

For analysis of current requirements/stock situation, choose Logistics → Production → MRP → Evaluations → Stock/Requirements List or use transaction MD04.

C S C

c)

Enter transaction type 561, plant 1000, storage location 0001, today's date as document and Posting Date, and leave the other fields empty or enter default differences.

d)

For any necessary issues of goods choose Logistics → Materials Management → Inventory Management → Goods Movement → Goods Issue or use transaction MB1A.

e)

Use the movement category 201 and the cost center 1000.

i n t e r n a l

b y

For any necessary deliveries of goods, choose Logistics → Materials Management → Inventory Management → Goods Movement → Goods Receipt → Other or use transaction MB1C.

b y

i n t e r n a l

u s e

u s e

b)

F o r

o n l y

Stock is displayed in the top line.

C S C

F o r

o n l y

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2.

PLM114

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, Priority 1, Strategy 2, and Usage probability 100. For item T-Z##, enter Alt.item group 01, Priority 2, Strategy 2, and Usage probability 1. a)

Add component T-Z##.

C S C

c)

Set T-Z## as an alternative to T-B1##.

d)

Select both components on the General Item Overview screen and select Details .

e)

In the details for component T-B1##, enter AltItemGroup 01 and press ENTER.

f)

Enter the following in the Alternative Item Data dialog box. Entry

Priority

1

Strategy

2

Usage Prob.

100 to proceed to the details for

h)

In the details for component T-Z##, enter AltItemGroup 01 and press ENTER.

C S C

i)

Enter the following in the Alternative Item Data dialog box.

F o r

Press ENTER and choose Next Item component T-Z##.

Field

Entry

Priority

2

Strategy

2

Usage Prob.

1

j)

Press ENTER.

k)

Save the BOM.

o n l y

g)

b y

i n t e r n a l

Field

u s e

u s e

b y

In the first available row, enter item T-Z## with the quantity 1 piece.

Continued on next page

364

i n t e r n a l

b)

F o r

o n l y

Choose Logistics -> Production -> Master Data -> Bills of Material -> Bill of Material -> Material BOM -> Change or use transaction code CS02.

© 2006 SAP AG. All rights reserved.

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PLM114

Lesson: Discontinuation and Substitute Parts in the Bill of Material

Task 2: Optional: Using a production order, test the effects of the alternative item(s). 1.

Test the effects of the alternative item group on production planning and material backflush.

____________

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##?

____________

i n t e r n a l

C S C

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

Caution: Do not save the order yet.

Enter the material number, plant, and order type on the initial screen and press ENTER.

c)

On the next screen, enter the total quantity and the order finish date of today + 1 month and press ENTER.

d)

Go to the Components overview using the

varies

Confirmed quantity of T-B1##

0

Quantity requirement of T-Z##

1

Confirmed quantity of T-Z##

0

o n l y

F o r

button.

C S C

i n t e r n a l

u s e

b y

b)

Caution: Do not save the order at this point. 2.

Carry out an availability check for all components.

Continued on next page

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b y

To create a production order, choose Logistics → Production→ Production Control→ Order→ Create→ With Material or use transaction code CO01.

u s e

a)

Quantity requirement of T-B1##

F o r

o n l y

Create a production order for the material T-F1## in plant 1000 for LESS 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 to find the answers to the following questions:

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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##?

____________

Exit and do not save the order.

C S C

Quantity requirement of T-B1##

varies (ALL)

Confirmed quantity of T-B1##

varies (ALL)

Quantity requirement of T-Z##

0

Confirmed quantity of T-Z##

0

Repeat the last two steps to test the effect of the alternative item groups in the case of insufficient stock.

i n t e r n a l

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##?

____________

o n l y

F o r

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

varies (ALL)

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. Continued on next page

366

C S C

____________

b y

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

u s e

u s e

b y

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 your data entries with ENTER, go to the Component overview to find the answers to the following questions:

i n t e r n a l

3.

Choose Availability Check .

F o r

o n l y

a)

© 2006 SAP AG. All rights reserved.

2006/Q2

PLM114

Lesson: Discontinuation and Substitute Parts in the Bill of Material

4.

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##?

____________

Do not save the order.

C S C

0

Confirmed quantity of T-B1##

0

Quantity requirement of T-Z##

varies (ALL)

Confirmed quantity of T-Z##

varies (ALL)

b y

i n t e r n a l

u s e

u s e

b y

Exit without saving the order.

i n t e r n a l

Quantity requirement of T-B1##

F o r

o n l y

a)

C S C

F o r

o n l y

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Lesson Summary You should now be able to: • Demonstrate and explain the discontinuation process. • Model item substitutions in the bill of material

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

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PLM114

Lesson: Multiple and Variant BOMS

Lesson: Multiple and Variant BOMS Lesson Overview Variant and multiple bills of material are a method to manage BOMs. We will discuss the circumstances and advantages of each.

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

o n l y

Discuss the advantages of using multiple and variant BOMs Create a multiple BOM Create a variant BOM Define variant configuration

F o r

• • • •

C S C

b y

Two situations many occur that may increase the number of BOMs that need to be managed. First, a single material may have more then one list of components. We will use multiple BOMs to manage these. Second, many materials may use similar components. We will use variant BOMs for these.

u s e

C S C

i n t e r n a l

b y

One product may be made of different combinations of components, depending on the quantity (lot size) to be manufactured or the date. This type of product is often represented by alternative BOMs (alternatives). These alternative BOMs differ only slightly from one another, usually in terms of the component quantity.

u s e

Multiple BOMs

i n t e r n a l

Business Example

F o r

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C S C

All alternatives for a multiple BOM are saved under one internal BOM number.

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

u s e

b y

i n t e r n a l

u s e

You can assign one name to all the alternatives in a multiple BOM by entering a BOM group in the BOM header.

i n t e r n a l

b y

o n l y

F o r

Figure 143: Multiple BOM: One Product

C S C

F o r

o n l y

Figure 144: Multiple BOM

The plant and usage are part of the unique key that identifies a BOM. Each alternative has a BOM header.

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Lesson: Multiple and Variant BOMS

The alternative is selected according to the selection method indicator in the material master record: • • •

Lot size Date Production version

Variant BOMs If several similar products are manufactured whose parts only differ in minor ways, you can represent these various products using a variant BOM. Variants can also differ in component quantity alone.

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

Only a simple (basic) material BOM can be extended to become a variant BOM.

F o r

o n l y

You cannot convert a multiple BOM into a variant BOM.

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C S C

Figure 145: Variant BOM: Several Products

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o n l y

F o r

Figure 146: Variant BOM

You can create a variant only if:

C S C

b y

i n t e r n a l

u s e

u s e

b y

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.

i n t e r n a l

• •

C S C

F o r

o n l y

Figure 147: Variant BOM (2)

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 field BOM group can also be used as an external BOM number. The plant and the BOM usage are part of the unique key of a bill of material.

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Lesson: Multiple and Variant BOMS

Each variant has a BOM header. You can create a variant only if: • •

A BOM does not already exist for the material. The base unit of measure of all variant materials is the same. This is because the base unit of measure of the bill of material must be the same as the base unit of measure of the material master record.

o n l y

F o r

b y

C S C

i n t e r n a l

u s e

u s e

Figure 148: Different Types of BOMs

When dealing with multivariant products, the combinations of individual product features give rise to a vast range of variants.

C S C

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.

b y

i n t e r n a l

Variant Configuration

F o r

o n l y

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b y

However, this is not easy, as product development cycles and life cycles of products are becoming shorter than ever before.

u s e

C S C

i n t e r n a l

b y

The features of configurable products are defined the SAP system as characteristics.

u s e

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.

i n t e r n a l

C S C

o n l y

F o r

Figure 149: Variant Configuration

F o r

o n l y

Figure 150: Configuration of a Pump

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Lesson: Multiple and Variant BOMS

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: • •

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 motorcycle, you may only be able to have certain colors of paint and seats if you are ordering an expensive model.

Instead of creating a separate BOM for each product variant, you can group the components together into a super BOM. This super BOM consists of 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.

o n l y

F o r

In the sales order, an individual product structure is created dynamically.

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

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F o r

Unit 7: Advanced Bill of Material Functions

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

© 2006 SAP AG. All rights reserved.

PLM114

Lesson: Multiple and Variant BOMS

Exercise 19: Multiple/Alternative Bills of Material Exercise Objectives After completing this exercise, you will be able to: • Maintain an alternative/multiple BOM

Business Example You need to group together bills of material for “blue paint” in a multiple BOM.

o n l y

The BOM for “blue paint” (material number T-F77## (## = group number) has different components or component quantities for different lot sizes.

C S C

Create a BOM for the paint in plant 1000 with the following data:

i n t e r n a l

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 the item below and change the quantity of item 20: Item cat.

Component

Quantity

Un

10

L

T-B72

0.3

kg

o n l y

Item

Change the quantity of component T-B74 in item 20 to 1.4 l. 3.

4.

Create another alternative by copying alternative 1. In this alternative, replace item 10, component T-B71, with the following: Item

Item cat.

Component

Quantity

Un

10

L

T-B73

0.3

kg

Add the following data to the BOM headers of the alternatives: Continued on next page

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© 2006 SAP AG. All rights reserved.

C S C

F o r

Item cat.

b y

2.

Item

u s e

u s e

b y

Material T-F77##, BOM group Color-##, and BOM text ‘multiple BOM group ##’.

i n t e r n a l

1.

F o r

Task: Maintaining Alternative/Multiple BOMs

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5.

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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

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

The production order should be for plant 1000, order type PP01, for more than 125 pieces and for 2 months from 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 ______________________________

u s e

7.

b y

i n t e r n a l

Alternative ____ because ______________________________ Optional: Maintain a multiple BOM for the different alternatives.

C S C

Select of alternatives according to date.

Material

Plant

BOM usage

Valid from

BOM Alt

T-F77##

1000

1

01/01/xxxx

1

T-F77##

1000

1

01/07/xxxx

2

T-F77##

1000

1

01/12/xxxx

3

© 2006 SAP AG. All rights reserved.

2006/Q2

o n l y

F o r

Example:

378

u s e

Change the order quantity to 225 pieces and update the PP master data. Why this alternative?

i n t e r n a l

C S C

Optional: Create a production order with the material T-F77## and test the effects of the different BOM alternatives with your lot sizes.

b y

6.

F o r

o n l y

Technical type ____________

PLM114

Lesson: Multiple and Variant BOMS

Solution 19: Multiple/Alternative Bills of Material Task: Maintaining Alternative/Multiple BOMs The BOM for “blue paint” (material number T-F77## (## = group number) has different components or component quantities for different lot sizes. 1.

Create a BOM for the paint in plant 1000 with the following data: Material T-F77##, BOM group Color-##, and BOM text ‘multiple BOM group ##’.

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

i n t e r n a l

C S C

F o r

o n l y

Continued on next page

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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

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

b)

Enter the data from the table below.

Material

T-F77##

Plant

1000

Usage

1

Valid from

Today's date

Choose Enter

d)

On the Item overview screen, enter the following data:

u s e

b y

c)

.

Item

Item cat.

Component

Quantity

10

L

T-B71

0.5

20

L

T-B74

1

30

L

T-B75

1

f)

Go to the BOM Header

g)

In the BOM Group field, enter PAINT-##.

h)

Save the BOM.

.

Create an alternative by copying alternative 1. In this alternative, replace item 10, component T-B71, with the item below and change the quantity of item 20: Item

Item cat.

Component

Quantity

Un

10

L

T-B72

0.3

kg

Continued on next page

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o n l y

Give the BOM group a name:Paint-##.

C S C

e)

b y

i n t e r n a l

Entry

u s e

F o r

Field

i n t e r n a l

C S C

o n l y

a)

F o r

2.

PLM114

PLM114

Lesson: Multiple and Variant BOMS

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

b)

Enter the data from the table below.

Material

T-F77##

Plant

1000

Usage

1

Valid from

Today's date

d)

Confirm the warning “Alternative 2 added to BOM.”

e)

Enter alternative 1 in the dialog box and choose Enter.

f)

Select all of the components to copy and choose Copy

g)

Change the following two rows in the item overview:

u s e

b y

Select copy from

or press F7.

again.

Item no.

Item cat.

Component

Quantity

10

L

T-B72

0.3 kg

20

L

T-B74

1.41

u s e

Save the BOM

b y

Create another alternative by copying alternative 1. In this alternative, replace item 10, component T-B71, with the following:

C S C

i n t e r n a l

Entry

c)

h) 3.

Field

i n t e r n a l

C S C

a)

F o r

o n l y

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

F o r

o n l y

Continued on next page

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C S C

Item cat.

Component

Quantity

Un

10

L

T-B73

0.3

kg

a)

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

b)

Enter the data from the table below. Entry

Material

T-F77##

Plant

1000

Usage

1

Valid from

Today's date

Select copy from

d)

Confirm the warning “Alternative 3 added to BOM.”

e)

Enter Alternative 1 in the dialog box and choose Enter.

f)

Select all of the components to copy and choose Copy

g)

Change the following in the item overview:

u s e

c)

or choose F7.

again.

Item no.

Item cat.

Component

Quantity

10

L

T-B73

0.3 kg

u s e

b y

Save the BOM

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

C S C

i n t e r n a l

Field

i n t e r n a l

b y

Item

h) 4.

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Unit 7: Advanced Bill of Material Functions

F o r

o n l y

Continued on next page

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Lesson: Multiple and Variant BOMS

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

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change:

b)

Enter the data from the table below.

T-F77##

Plant

1000

Usage

1

Valid from

Today's date

c)

Select alternative 1 and select the Header icon

d)

On the Quantities/Long text tab page, (F6) add the following: Alt text. Paint Color 1 and lot size from 1 to 100.

e)

Repeat steps for alternatives 2 and 3.

b y

C S C

Material

.

u s e

u s e

Entry

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

b y

i n t e r n a l

i n t e r n a l

5.

Field

F o r

o n l y

a)

BOM group ____________

C S C

Internal BOM number ____________

F o r

o n l y

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Technical type ____________ a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → BOM Group → Display:

b)

Enter the data from the table below.

o n l y

Entry

BOM group

Paint-##

Plant

1000

Usage

1

Valid from

Today's date

Choose Goto → Alternative overview. Three alternatives should now be displayed. Select all alternatives and choose the Header icon .

C S C

the Next alternative icon

b y

d)

.

BOM number, usage 1 and technical type M should be the same in all alternatives.

u s e

Optional: Create a production order with the material T-F77## and test the effects of the different BOM alternatives with your lot sizes.

F o r

Change the order quantity to 225 pieces and update the PP master data. Why this alternative?

Continued on next page

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o n l y

Alternative ____ because ______________________________

C S C

The production order should be for plant 1000, order type PP01, for more than 125 pieces and for 2 months from 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?

b y

i n t e r n a l

6.

u s e

Alternative texts and lot sizes should be different for each alternative (see defaults).

i n t e r n a l

Hint: Switch between the three different alternatives using

F o r

c)

Field

PLM114

Lesson: Multiple and Variant BOMS

Alternative ____ because ______________________________ a)

Choose Logistics → Production → Production control → Order → Create → with material.

b)

Enter the data from the table below. Entry

Material

T-F77##

Production plant

1000

Order type

PP01

Choose Enter. Enter the following data.

F o r

125

Order finish date

2 months from today

i n t e r n a l

e)

Choose generate process.

f)

On the Master data tab page, enter BOM Alt. quantity).

g)

Now change quantity to 225 pieces. Choose Functions → Read PP master data → Read BOM only. Enter BOM Alt. 3 (because of quantity).

h)

Exit the order without saving.

Choose Enter.

7.

2 (because of

C S C

i n t e r n a l

u s e

Ignore the message “ no working schedule found .”

Optional: Maintain a multiple BOM for the different alternatives. Select of alternatives according to date.

F o r

o n l y

Example:

Continued on next page

2006/Q2

b y

d)

u s e

C S C

Total quantity

b y

o n l y

c)

Field

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Material

Plant

BOM usage

Valid from

BOM Alt

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)

Choose 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 or use transaction code CS05....

b)

On the initial screen, choose Settings → Current settings.

c)

Double-click the Execute icon to view the multiple BOM.

d)

Maintain data as described in exercise and Save.

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Lesson: Multiple and Variant BOMS

Exercise 20: Variant BOMs Exercise Objectives After completing this exercise, you will be able to: • Maintain a variant BOM

Business Example The engineering department requires BOMs to efficiently maintain simple but similar materials.

Task:

BOM text

“Standard pump”

Alternative Text

Y variant and Z variant

BOM group

VA##

2.

Create a BOM for pump T-FZ## as a variant of T-F##. Replace component 100-300 with T-BZ##.

3.

Display all variants of T-F## (BOM group VA##).

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4.

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_______________

Internal BOM number

_______________

Technical type

_______________

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Check your entries are correct. Check in particular: BOM group

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.

© 2006 SAP AG. All rights reserved.

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Create a BOM for pump T-FY## as a variant of T-F##. Replace component T-B## with T-B1##. Enter the following header data.

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1.

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These are pumps T-FY## and T-FZ##.

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You now want to create two additional variants of the pump T-F## in plant 1000 with where-used list 1.

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Solution 20: Variant BOMs Task: 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##. 1.

Create a BOM for pump T-FY## as a variant of T-F##. Replace component T-B## with T-B1##. Enter the following header data.

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Continued on next page

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Lesson: Multiple and Variant BOMS

BOM text

“Standard pump”

Alternative Text

Y variant and Z variant

BOM group

VA##

a)

Create an additional variant for pump T-FY##. Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create .

C S C

Material

T-FY##

Plant

1000

(Default)

Usage

1

(Default)

Valid from

Today's date

(Default) do not press

c)

Choose

d)

Enter Material T-F## in the Create variant of... dialog box.

.

.

e)

Select all components to be copied and choose the Copy icon

f)

Enter header data from the table below:

.

b y

VA##

BOM text

Standard pump

Alt text

Y variant

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BOM group

F o r

h)

o n l y

Confirm with Enter. g)

In the Item Overview, change the component below: Item no.

Item cat.

Component

Quantity

10

L

T-B1##

1

Save the BOM.

Continued on next page

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Choose Enter

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Enter the data below.

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b)

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Create a BOM for pump T-FZ## as a variant of T-F##. Replace component 100-300 with T-BZ##. a)

Create additional variant for pump T-FZ##. Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create .

C S C

Material

T-FZ##

Plant

1000

(Default)

Where-used list

1

(Default)

Valid from

Today's date

(Default) do not press

Choose

.

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c)

Enter the following data.

Select all components to be copied and choose the Copy icon .

f)

In the Item Overview, change the component below: Item no.

Item cat.

Component

Quantity

30

L

T-BZ##

1

b y

Save the BOM.

C S C

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e)

g) 3.

.

Choose Enter

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Enter Material T-F## in the Create variant of... dialog box. d)

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b)

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

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Continued on next page

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Lesson: Multiple and Variant BOMS

BOM group

_______________

Internal BOM number

_______________

Technical type

_______________

a)

Display your BOM group. Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → BOM Group → Display. Enter the following data. BOM group

VA##

Plant

1000

Valid From

Today's date

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c)

Select Variants .

d)

Select all variants and choose the Header button

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Choose Enter. .

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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)

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In the summarized BOM, choose Variant items to view selected items.

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Hint: In the header, choose : Item. You can then move between the individual variants using the Previous Variants and Next Variants buttons.

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b y

BOM number, usage 1, and technical type V exist only once.

Change your BOM group. Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → BOM Group → Change.

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b)

Enter BOM Group VA## and press ENTER.

c)

Enter component material 100-801 and a quantity in the first available component item, and set the Item indicator in alternative/variant 02 and 03 for variants T-FY## and T-FZ##.

d)

Save the BOM.

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Lesson Summary You should now be able to: • Discuss the advantages of using multiple and variant BOMs • Create a multiple BOM • Create a variant BOM • Define variant configuration

Related Information Variant configuration is taught in the following SAP courses:

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PLM130 Classification PLM140 Variant Configuration 1 – Modeling PLM143 Variant Configuration 2 – Integration WNAP45 Variant Configuration 1 & 2 - Modeling and Integration PLM146 Variant Configuration 3 – Scenarios

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• • • • •

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Lesson: Mass Changes and the Product Structure Browser

Lesson: Mass Changes and the Product Structure Browser Lesson Overview In this lesson, we will discuss mass changes and the product structure browser in bills of material.

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

o n l y

Update BOMs using mass changes Navigate the product structure browser

F o r

• •

Business Example

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All the objects in a structure have to be displayed, processed, or created.

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Mass Changes and the Product Structure Browser

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You can use the mass change function to make changes to items in several BOMs using only one function call.

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A component material is used on many BOMs and must be replaced.

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Figure 151: Mass Change in BOMs

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• • • •

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 In all selected BOMs Using Engineering Change Management if necessary With restrictive selection criteria, such as plant and/or usage

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– – –

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The following item changes are supported for material items, document items, and class items:

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Figure 152: 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 (Application Link Enabling [ALE] destinations).

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Lesson: Mass Changes and the Product Structure Browser

You can: • • • • •

Go directly to display mode or processing mode for individual objects Display or process similar objects Create an additional tree structure for any object Select several objects for object management records in Engineering Change Management Jump to the engineering workbench

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PLM114

Lesson: Mass Changes and the Product Structure Browser

Exercise 21: Mass Changes and the Product Structure Browser Exercise Objectives After completing this exercise, you will be able to: • Analyze and navigate your product structure

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

o n l y

F o r

Task: Navigate the Product Structure Browser

C S C

Take a look at the product structure for material T-F##.

i n t e r n a l

1.

Display the BOM and open a document info record.

b y

Display the BOM for the assembly. 2.

Change item 0010 for BOM T-F## in plant 1000.

3.

u s e

u s e

Double the required quantity for component 0010. Go to the classification and display the characteristics for your pump.

b y

i n t e r n a l

Pump height: ____________ Pump capacity: ____________

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Usage: ____________

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Solution 21: Mass Changes and the Product Structure Browser Task: Navigate the Product Structure Browser 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 the product structure browser

o n l y

C S C

Enter the material T-F## on the Material tab page and choose Enter

Double-click on the symbols for bill of material or document to display the corresponding master record. You can also click on the eyeglasses to the right to display the documents.

e)

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.

f)

To recognize which T-F## components are also assemblies, we recommend placing the assemblies indicator in the layout.

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F o r

and choose

g)

Select the right-hand side of the Filter button BOM item.

h)

Highlight the Assembly field and move to the left using the and then choose Enter.

i)

To display the BOM of an assembly, expand the appropriate node and right-click.

button

Change item 0010 for BOM T-F## in plant 1000. Continued on next page

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.

Select the right-hand side of the Change Layout button

2.

C S C

d)

b y

Expand the tree structures for bills of material and documents by clicking on the hierarchy node.

u s e

c)

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b y

.

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b)

F o r

Choose Cross-Application Components → Engineering Change Management → Environment → Product Structure or Logistics → Central Functions → Engineering → Engineering Change Management → Environment → Product Structure.

PLM114

Lesson: Mass Changes and the Product Structure Browser

Double the required quantity for component 0010.

3.

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.

b)

Double-click on the item number 0010.

c)

Change the required quantity.

d)

Choose Save.

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

Expand the hierarchy node Classification and select the Class.

b)

Right-click and select Characteristic Value Assignment or choose the

C S C

c)

i n t e r n a l

Values icon

.

Pump height: 5 m (may vary) Pump capacity: 15 m3 (may vary)

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Usage: ____________

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Usage: House technology (may vary)

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Lesson Summary You should now be able to: • Update BOMs using mass changes • Navigate the product structure browser

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Unit Summary

Unit Summary

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You should now be able to: • Explain the concept of a phantom BOM and when it should be used • Create a phantom BOM in SAP R/3 • Maintain phantom bills of material • Demonstrate model co-products and by-products • Demonstrate and explain the discontinuation process. • Model item substitutions in the bill of material • Discuss the advantages of using multiple and variant BOMs • Create a multiple BOM • Create a variant BOM • Define variant configuration • Update BOMs using mass changes • Navigate the product structure browser

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Test Your Knowledge

Test Your Knowledge 1.

A component with a negative quantity exists on a BOM. Select each of the following that it could be. Choose the correct answer(s).

□ □ □ □ 2.

A B C D

Co-product By-product Waste product Recursive product

Co-products, by-products, and waste products are materials on the BOM which you can choose to produce.

o n l y

3.

True False

One of the differences between co-products, by-products, and waste products is their inventory valuation and settlement.

b y

Determine whether this statement is true or false.

u s e

In order to use a material on a BOM as a co-product, you must first enable it to be used as a co-product in the material master. Determine whether this statement is true or false.

True False

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□ □

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4.

True False

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□ □

F o r

Determine whether this statement is true or false.

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Answers 1.

A component with a negative quantity exists on a BOM. Select each of the following that it could be. Answer: A, B, C A component on a BOM with a negative quantity could be a co-product, by-product, or a waste product.

2.

Co-products, by-products, and waste products are materials on the BOM which you can choose to produce.

o n l y

C S C

b y

3.

One of the differences between co-products, by-products, and waste products is their inventory valuation and settlement. Answer: True

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Answer: True

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In order to use a material as a co-product on a BOM you must set the co-product indicator on the MRP 2 view of its material master record. In addition, you should also define the apportionment structure under the joint production button for cost settlement.

C S C

In order to use a material on a BOM as a co-product, you must first enable it to be used as a co-product in the material master.

b y

4.

u s e

Co-products have non-zero inventory valuation and are earmarked for cost settlement. By-products have a non-zero inventory valuation but are not earmarked for cost settlement. Waste products have zero inventory valuation and are not earmarked for cost settlement.

i n t e r n a l

Co-products, by-products, and waste products are materials on the BOM that are created simultaneously with the main product. The main product cannot be produced in isolation without producing these.

F o r

Answer: False

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Unit 8 Advanced Routing Functions

Unit Overview

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After completing this unit, you will be able to:

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• • •

C S C

• •

b y

• •

Use parallel sequences in modeling complex manufacturing processes Use alternative sequences in modeling flexible manufacturing processes Model alternative manufacturing processes using alternative routings Use production versions to model a very specific production process Utilize reference operation sets to minimize routing maintenance Create a reference operation set Use a reference operation set in a routing Use a reference operation set as a template to create a routing Describe in detail the concept of lead time scheduling and updating in-house production time in the material master Identify the data used in lead time scheduling Explain how the SAP ERP system uses the data to determine the lead time schedule Update the material master record of a material from the routing Demonstrate the use of interoperation times in the routing for job shop related environments Demonstrate the use of Overlapping for a continuous manufacturing process Demonstrate the use of splitting for multi-capacity work centers. Describe the use of trigger points to streamline and automate several administrative processes

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• • • • • • • • •

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Unit Objectives

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This unit introduces several advanced concepts surrounding the use of routings in SAP ERP. Not all of the following functions will be required to use during the modeling of your company's manufacturing process. These functions will include the user of parallel and alternative operations, detailed scheduling segments, scrap and other miscellaneous functions.

Unit 8: Advanced Routing Functions

• • • •

PLM114

Explain how the assembly and component scrap in the material master field affect the production process Explain how the component scrap and operation scrap percentage in the bill of material affect the production process Explain how the scrap in the percentage field in the routing affects the production confirmation process Describe and use production resources/tools in the routing

Unit Contents

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Lesson: Modeling Complex and Flexible Manufacturing Processes .....407 Exercise 22: Creating Alternative and Parallel Sequences ........... 411 Lesson: Modeling Alternative Manufacturing Processes ..................418 Exercise 23: Creating Alternative Routings and Production Versions......................................................................421 Lesson: Reference Operation Sets...........................................431 Exercise 24: Reference Operation Sets .................................433 Lesson: Lead Time Scheduling and Material Master Updates............441 Exercise 25: Scheduling...................................................445 Lesson: Time Components, Reduction Possibilities in the Routing ......450 Exercise 26: Time Elements of the Operation in Scheduling .........457 Lesson: Trigger Points in the Routing........................................464 Procedure: Setting Up a Trigger Point...................................466 Lesson: Scrap and Its Effects .................................................468 Exercise 27: Scrap in Production ........................................473 Lesson: Production Resources/Tools ........................................480 Exercise 28: Creating and Assigning PRTs .............................483

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PLM114

Lesson: Modeling Complex and Flexible Manufacturing Processes

Lesson: Modeling Complex and Flexible Manufacturing Processes Lesson Overview In this lesson you will discuss the use of parallel and alternative sequences to model complex and flexible manufacturing processes.

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

o n l y

Use parallel sequences in modeling complex manufacturing processes Use alternative sequences in modeling flexible manufacturing processes

Business Example

C S C

b y

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F o r

Parallel sequences are special types of overlapping operations that can be used in various industries. A parallel sequence enables you to process several operations at the same time. It is carried out at the same time as the corresponding section in the standard sequence. It is a special form of overlapping operations.

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407

o n l y

In the simplest case a routing only has one sequence, the standard sequence. Every other sequence is either an alternative or a parallel sequence, depending on whether its operations are performed as an alternative to the standard sequence or in parallel (at the same time) with the standard sequence. Only routings can have alternative sequences, parallel sequences can be created in both routings and rate routings.

C S C

You use a single sequence to represent a simple linear series of production steps in production. If you want to represent a more complex series of production steps, you link several sequences with relationships to predecessors and successors.

b y

Parallel Sequences

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In addition, you have some machines that are identical in nature. For capacity planning purposes, you can switch jobs between the machines with little or no effect on the subsequent operations. You would like to use alternative sequences to model this flexible manufacturing opportunity.

i n t e r n a l

Within the project team, you are responsible for routing management. You have several products that undergo complex manufacturing steps. Due to the unique nature of the process, several operations must occur simultaneously. In order to due this, you want to make use of parallel sequences in the routing.

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For example, in mechanical engineering for assembly lines with individual component manufacturing, a parallel sequence allows for several individual components from the BOM to be prepared as smaller units for final assembly. In the chemical industry, parallel sequences can be used to model analytical processes that occur parallel to the production process.

b y

u s e

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F o r

A linear sequence of operations that is an alternative to a sequence of operations in the standard sequence.

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Alternative Sequences in Routings

C S C

You can create parallel sequences in routings and rate routings. You cannot create them in reference operation sets or reference rate routings

b y

Only the first operation of a referenced operation set (or reference rate routing) that has not been unlocked can be used as a branch or as a return operation for alternative or parallel sequences. To use other operations within a reference operation set (or reference rate routing) for your parallel sequence, you must first unlock the reference.

u s e

An alignment key defines the start of the individual parallel sequences and, consequently, the position of the sequence buffers.

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Figure 153: Sequence Scheduling

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Lesson: Modeling Complex and Flexible Manufacturing Processes

You use an alternative sequence for example, if: •

•

The production flow is different for certain lot-size ranges For instance you can machine a work piece on conventional machine or on NC machines. A NC machine has a longer set-up time than a conventional machine. However the machining costs are considerably less. Therefore whether you use NC machines will depend on the lot size. The production flow changes under certain business conditions. For instance, if you have a capacity problem, you have some production steps performed externally by a vendor.

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Alternative sequences are linked to the standard sequence. Branch operations in the standard sequence are ignored in the procedure.

F o r

You can enter a lot-size range, so that the system automatically selects the alternative sequence if an order lies within this range. The lot size range of an alternative sequence can differ from the one specified in the routing header. However, it must overlap at least partially with the lot size range in the routing header.

C S C

F o r

Only the first operation of a referenced operation set that has not been unlocked can be used as a branch or as a return operation for alternative or parallel sequences. To use other operations within a reference operation set for your alternative sequence, you must first unlock the reference. You can only create alternative sequences in routings. You cannot create them in reference operation sets, reference rate routings or rate routings.

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Figure 154: Alternative Sequences

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PLM114

Lesson: Modeling Complex and Flexible Manufacturing Processes

Exercise 22: Creating Alternative and Parallel Sequences Exercise Objectives After completing this exercise, you will be able to: • Create a parallel sequence • Allocate components to an operation in the parallel sequence

Business Example

o n l y

C S C

Create a routing with a parallel sequence for your finished material T-F## and allocate components to both the standard sequence and the parallel sequence. First, create the standard sequence of the routing for the production of material T-F## in plant 1000, which consists of the five steps in the table below. The routing should be creation status, valid from today's date, for production usage, and for lot sizes from 1 to 100,000 pieces. Use the data in the table below to complete the routing information.

Work Center

Control Key

Description

10

T-M##

PP01

Material staging by picking list

20

T-E##

PP01

Preassemble pump components

30

T-F##

PP01

Final assembly of pump

40

T-P##

PP99

Deliver to stock

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Operation #

C S C

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Primary Operation Data:

Standard Processing Times: Activity

Op 10

Op 20

Op 30

Op 40

Setup

0 Min

10 Min

15 Min

0 Min

Machine

0 Min

10 Min

10 Min

0 Min

Labor

10 Min

10 Min

10 Min

5 Min

Continued on next page

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1.

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Task:

F o r

In your manufacturing process, you have steps in the process that are being done simultaneously. You would like to model this complex manufacturing process using parallel sequences.

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2.

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Create the parallel sequence of the routing for the production of material T-F## in plant 1000, which consists of the three steps in the table below. Use the data in the table below to complete the routing information. Parallel Sequence Operation Data: Operation #

Work Center

Control Key

Description

10

T-V##

PP01

Cut sheet metal

20

T-V##

PP01

Drill and tap holes

30

T-L##

PP01

Cover and paint

C S C

b y

Op 20

Op 30

Setup

10 Min

0 Min

15 Min

Machine

10 Min

0 Min

5 Min

Labor

0 Min

5 Min

5 Min

Assign material components from the BOM of T-F## to specific operations on the routing. Assign 100-700 to operation 10 of the parallel sequence and 100-600, 100-130, and the non-stock item to operation 30 of the standard sequence.

b y

i n t e r n a l

Where will the other components that you haven't assigned be allocated?

u s e

u s e

Op 10

i n t e r n a l

3.

Activity

F o r

o n l y

Standard Processing Times:

C S C

F o r

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Lesson: Modeling Complex and Flexible Manufacturing Processes

Solution 22: Creating Alternative and Parallel Sequences Task: Create a routing with a parallel sequence for your finished material T-F## and allocate components to both the standard sequence and the parallel sequence. 1.

First, create the standard sequence of the routing for the production of material T-F## in plant 1000, which consists of the five steps in the table below. The routing should be creation status, valid from today's date, for production usage, and for lot sizes from 1 to 100,000 pieces. Use the data in the table below to complete the routing information.

o n l y

C S C

b y

Operation #

Work Center

Control Key

Description

10

T-M##

PP01

Material staging by picking list

20

T-E##

PP01

Preassemble pump components

30

T-F##

PP01

Final assembly of pump

40

T-P##

PP99

Deliver to stock

i n t e r n a l

u s e

u s e

F o r

Primary Operation Data:

b y

i n t e r n a l

Standard Processing Times:

C S C

F o r

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C S C

b y

u s e

Op 20

Op 30

Op 40

Setup

0 Min

10 Min

15 Min

0 Min

Machine

0 Min

10 Min

10 Min

0 Min

Labor

10 Min

10 Min

10 Min

5 Min

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Create or use transaction code CA01.

b)

Enter the material T-F## and plant 1000 and choose Enter

c)

Enter usage 1 for production, status 1 for creation phase, planner group 0##, and lot size of 1 to 100,000 pieces.

d)

and enter Choose the Operations Overview icon the primary operation data from the table. Respond to any system messages that appear.

e)

Select all operations and choose Details → Operation from the menu. Enter the standard operation processing Times from the table and to navigate to the next operation detail screen. Continue choose until all times have been entered and then choose to return to the operation overview.

f)

Save your routing.

.

Create the parallel sequence of the routing for the production of material T-F## in plant 1000, which consists of the three steps in the table below. Use the data in the table below to complete the routing information. Parallel Sequence Operation Data:

b y

Work Center

Control Key

Description

10

T-V##

PP01

Cut sheet metal

20

T-V##

PP01

Drill and tap holes

30

T-L##

PP01

Cover and paint

o n l y

Operation #

C S C

i n t e r n a l

Op 10

u s e

F o r

Activity

Standard Processing Times:

Continued on next page

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Lesson: Modeling Complex and Flexible Manufacturing Processes

Op 20

Op 30

Setup

10 Min

0 Min

15 Min

Machine

10 Min

0 Min

5 Min

Labor

0 Min

5 Min

5 Min

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter the material T-F## and plant 1000 and choose Enter

c)

Choose the Sequence Overview icon . Notice only the standard sequence is listed and this one is always numbered 0.

d)

Choose the Create icon

e)

Accept the default sequence number, enter Cut and paint sheet metal as the description, select the alignment key Align with latest dates, and enter reference sequence 0 and return operation 20.

f)

and enter the Choose the Operations Overview icon parallel sequence operation data from the table. Respond to any system messages that appear with No.

g)

Select all operations and choose Details → Operation from the menu. Enter the standard operation processing times from the table and to navigate to the next operation detail screen. Continue choose until all times have been entered and then choose to return to the operation overview.

h)

Choose the Sequence Overview icon again. Notice there are now two sequences: the standard sequence number 0 and the parallel sequence number 1.

i)

Select both sequences by clicking the button to the left of each and

to return to the sequence overview and save your routing.

Assign material components from the BOM of T-F## to specific operations on the routing. Assign 100-700 to operation 10 of the parallel sequence and 100-600, 100-130, and the non-stock item to operation 30 of the standard sequence.

u s e

F o r

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415

o n l y

Choose

C S C

k)

to view the graphic details of your

b y

Choose the Expand All icon routing.

u s e

j)

.

i n t e r n a l

i n t e r n a l

and select Parallel sequence.

choose the Operation Graphic icon

3.

.

F o r

b y

a)

o n l y

Op 10

C S C

Activity

Unit 8: Advanced Routing Functions

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Where will the other components that you haven't assigned be allocated? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

Chose the Component Allocation icon on the tool bar and select the alternative 1 Bill of Material.

d)

Select items 100-700 from the BOM that appears. Choose the New Assignment icon on the tool bar

e)

.

.

You can enter sequence 1 operation 10 in the Activity field or choose

o n l y

C S C

g)

Choose Save

h)

All other components that have not been assigned to any operation will default to the first operation of the standard sequence.

to save your routing and exit.

b y

i n t e r n a l

u s e

u s e

b y

Choose Continue and repeat steps d) through e) for components 100-300, 100-130, and the non-stock item, assigning them to operation 30 of sequence 0.

i n t e r n a l

f)

F o r

to select the operation from a list.

C S C

F o r

o n l y

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Lesson: Modeling Complex and Flexible Manufacturing Processes

Lesson Summary You should now be able to: • Use parallel sequences in modeling complex manufacturing processes • Use alternative sequences in modeling flexible manufacturing processes

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

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Lesson: Modeling Alternative Manufacturing Processes Lesson Overview In this lesson we will discuss the use of alternate routings to model alternative manufacturing processes. You will also learn about the use of production versions.

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

Model alternative manufacturing processes using alternative routings Use production versions to model a very specific production process

o n l y

C S C

b y

Alternative Routings

b y

i n t e r n a l

u s e

u s e

Different production lot sizes may require alternative production methods for reasons of efficiency.

i n t e r n a l

Within the project team, you are responsible for routing management. Several of your products require specific production cycles that are lot-size dependent. To model this in SAP ERP, you must create routing alternatives for these products.

F o r

Business Example

C S C

F o r

o n l y

Figure 155: Routings

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Lesson: Modeling Alternative Manufacturing Processes

The same material can be produced with different routings. The different routings can be from different plants. A single product with one BOM can be manufactured using different technologies. You might use an automatic assembly line for large quantities and a manual assembly line for small quantities. The end result, however, is the same material for both assembly lines. A product can be made of different combinations of components, depending on the quantity (lot size) to be manufactured. This type of product is represented by alternative BOMs. A product can have up to 1000 alternative BOMs that only differ slightly, usually in terms of the component quantity.

o n l y

C S C

b y

u s e

C S C

i n t e r n a l

b y

In the example illustrated below, a product is manufactured using two sets of technologies and methods. This necessitates different routings and different BOMs.

u s e

Production Versions

i n t e r n a l

Each routing requires a BOM for the product representing the unique components consumed by each manufacturing process. The selection of alternatives is controlled by the material master record and could be based on lot size, date, or production version.

F o r

In the above example, a single product is manufactured using different manufacturing technologies, which require different bills of material. This necessitates not only different routings, but also different BOMs. Machine 1 represents the older technology where the product is assembled from two previously assembled components. Machine 2 is a newer piece of equipment supporting the assembly of the product from four raw materials.

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o n l y

F o r

C S C

Version 0001 produces brackets for large order lots on an NC punching machine. The bracket is punched whole from a metal sheet.

i n t e r n a l

C S C

You can store multiple production versions for different lot size intervals in the material master. The group counter values differentiate the individual routings.

b y

The appropriate alternative is selected using the production version in the material master. The production version determines the manufacturing process according to the routing and BOM specified.

u s e

u s e

b y

Because it takes longer to set up a NC punching machine than the actual time it takes for punching, version 0002 is used to produce small quantities of brackets with another manufacturing process. This process requires strips of metal.

i n t e r n a l

Figure 156: Production Versions

F o r

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Lesson: Modeling Alternative Manufacturing Processes

Exercise 23: Creating Alternative Routings and Production Versions Exercise Objectives After completing this exercise, you will be able to: • Create an alternative routing

Business Example

o n l y

b y

Create a second routing to model an alternate manufacturing process. This manufacturing process is only to be used for small lot sizes. Create a second routing for the production of material T-B## in plant 1000, which consists of the five steps in the table below. The routing should be creation status, valid from today's date, for production usage, and for lot sizes from 1 to 100 pieces. Use the data in the table below to complete the routing information.

u s e

Work Center

Control Key

Description

10

1112

PP01

Lathe casing

20

1114

PP01

Drill holes

30

1310

PP01

Preassembly

40

1310

PP01

Final assembly

50

1310

PP01

Deliver to stock

C S C

i n t e r n a l

Operation #

b y

o n l y

F o r

u s e

Primary Operation Data:

Standard Processing Times: Activity

Op 10

Op 20

Op 30

Op 40

Op 50

Setup

10 Min

10 Min

0 Min

0 Min

0 Min

Machine

30 Min

10 Min

0 Min

0 Min

0 Min

Labor

30 Min

10 Min

5 Min

5 Min

10 Min

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i n t e r n a l

1.

F o r

Task 1:

C S C

You have two different ways of manufacturing your product, T-B##. You need another routing to model the manufacturing options.

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Task 2: Display your routing and answer the following questions. 1.

Display your routing.

2.

What are the group number and group counter? How does this compare with the other routing for T-B##?

Task 3:

2.

Change the lot size on routing with group counter 1 so it is valid for lot sizes 11-100,000 and set the status to Released (general).

2.

Create another production version 0002 for the selection of BOMs and routings for T-B##. The production version should be valid from today until 12/31/9999, for lot sizes 1 to 10 pc. Use task list type routing with your routing for T-B## group counter 2, and use BOM alternative 1 with usage 1.

3.

For the system to select your routings by production versions for this material, you will need to change the Selection Method field on the MRP4 view of the material master.

u s e

i n t e r n a l

C S C

Create a production version 0001 for the selection of BOMs and routings for T-B##. The production version should be valid from today until 12/31/9999, for lot sizes 11 to 100,000 pc. Use task list type routing with your routing for T-B## group counter 1, and use BOM alternative 1 with usage 1.

b y

1.

Create production versions for the selection of routings.

u s e

Task 4:

i n t e r n a l

C S C

Assign component 100-120 to operation 30 and component 100-130 to operation 40 on your new routing with group counter 2.

b y

1.

F o r

o n l y

Assign components to operations on your alternate routing. Change the lot size so one routing is valid for small lot sizes 1-10 and the other is valid for large lot sizes 11-100,000. Be sure to release both routings for production.

F o r

o n l y

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Lesson: Modeling Alternative Manufacturing Processes

Solution 23: Creating Alternative Routings and Production Versions Task 1: Create a second routing to model an alternate manufacturing process. This manufacturing process is only to be used for small lot sizes. 1.

Create a second routing for the production of material T-B## in plant 1000, which consists of the five steps in the table below. The routing should be creation status, valid from today's date, for production usage, and for lot sizes from 1 to 100 pieces. Use the data in the table below to complete the routing information.

o n l y

C S C

b y

Operation #

Work Center

Control Key

Description

10

1112

PP01

Lathe casing

20

1114

PP01

Drill holes

30

1310

PP01

Preassembly

40

1310

PP01

Final assembly

50

1310

PP01

Deliver to stock

i n t e r n a l

u s e

u s e

F o r

Primary Operation Data:

b y

i n t e r n a l

Standard Processing Times:

C S C

F o r

o n l y

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Op 20

Op 30

Op 40

Op 50

Setup

10 Min

10 Min

0 Min

0 Min

0 Min

Machine

30 Min

10 Min

0 Min

0 Min

0 Min

Labor

30 Min

10 Min

5 Min

5 Min

10 Min

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Create or use transaction code CA01.

b)

Enter the material T-B## and plant 1000 and choose Enter

c)

In the Create routing overview screen, choose the Create icon

d)

The group counter defaults to the next available number, in this case 2. Enter usage 1 for production, status 1 for creation phase, planner group 0##, and lot size of 1 to 10 pieces.

e)

and enter Choose the Operations Overview icon the primary operation data from the table. Respond to any system messages that appear.

f)

Select all operations and choose Details → Operation from the menu. Enter the standard operation processing times from the table and choose to navigate to the next operation detail screen. Continue until all times have been entered and then choose to return to the operation overview and save your routing.

.

F o r

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03.

b)

Enter T-B## and plant 1000 and choose

c)

On the Routing overview screen, select the routing with group counter 2 and choose .

.

What are the group number and group counter? How does this compare with the other routing for T-B##? a)

The group number will vary but should be a number beginning with 50000____ and the group counter should be 2.

b)

The group number is the same as the group number for the other routing for T-B## but the group counter is different. Continued on next page

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o n l y

2.

Display your routing.

C S C

i n t e r n a l

b y

Display your routing and answer the following questions. 1.

u s e

Task 2:

i n t e r n a l

u s e

.

F o r

b y

a)

o n l y

Op 10

C S C

Activity

PLM114

Lesson: Modeling Alternative Manufacturing Processes

Task 3: Assign components to operations on your alternate routing. Change the lot size so one routing is valid for small lot sizes 1-10 and the other is valid for large lot sizes 11-100,000. Be sure to release both routings for production. 1.

Assign component 100-120 to operation 30 and component 100-130 to operation 40 on your new routing with group counter 2. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter T-B## and plant 1000 and choose

c)

On the Routing overview screen, select the routing with group counter

.

o n l y

d)

C S C

e)

You can enter operation 30 in the Activity field or choose to select the operation from a list.

b y

f)

Choose Continue

g)

Repeat steps c) through e) to assign item T-T3## to operation 40.

u s e

h)

Choose Save

F o r

.

2 and choose

Select item T-T2## from the BOM that appears. Choose the New .

i n t e r n a l

Assignment icon on the tool bar

.

u s e

b y

i n t e r n a l

to save your routing and exit.

C S C

F o r

o n l y

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Unit 8: Advanced Routing Functions

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter T-B## and plant 1000 and choose

c)

On the Routing overview screen, select the routing with group counter 1 and choose .

d)

Change the lot size fields to 11 to 100,000.

e)

Change the status to 4 Released (general).

f)

Click the Routings icon to return to the Routing overview.

g)

Deselect the routing with group counter 1, select the routing with group again. counter 2, and choose

h)

Change the status to 4 Released (general) and make sure the lot size is for 1 to 10.

i)

Choose Save

.

b y

i n t e r n a l

u s e

u s e

b y

to save your routing and exit.

i n t e r n a l

C S C

Change the lot size on routing with group counter 1 so it is valid for lot sizes 11-100,000 and set the status to Released (general).

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C S C

F o r

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Lesson: Modeling Alternative Manufacturing Processes

Task 4: Create production versions for the selection of routings. Create a production version 0001 for the selection of BOMs and routings for T-B##. The production version should be valid from today until 12/31/9999, for lot sizes 11 to 100,000 pc. Use task list type routing with your routing for T-B## group counter 1, and use BOM alternative 1 with usage 1.

You should now be able to enter the data for material T-B##, production version 0001, and text Normal Production. By hitting ENTER twice to work through the warning, the valid dates will default.

d)

You can continue to work in the table or you can double-click on the production version number 0001 and work in the detail screen to enter data, which might make data entry easier.

e)

Enter lot size 11 to 100,000 pc.

f)

In the Task List section, choose Routing from the list for Task List Type.

g)

Enter your routing's group number in the Group field. If you don't know the group number, you can find the correct routing by using the F4 search function or the drop-down list. Choose tab C: Search using material and choose Continue . Be sure to choose the routing with group counter 1.

h)

In the Bill of Material section, enter alternative BOM 1 and usage 1.

i)

Now you can close the detail screen by choosing

C S C

b y

u s e

i n t e r n a l

.

C S C

c)

b y

Delete all entries in the Selection condition fields except Material T-B## and Plant 1000. Then choose Enter .

u s e

b)

i n t e r n a l

Choose Logistics → Production → Master Data → Production Versions or use transaction code C223.

F o r

a)

o n l y

1.

F o r

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Unit 8: Advanced Routing Functions

b)

Delete all entries in the Selection condition fields except Material T-B## and Plant 1000. Then choose Enter .

c)

Now you should be able to enter the data for material T-B##, production version 0002, and text Small Lot Size Production. By hitting ENTER twice to work through the warning, the valid dates will default.

d)

You can continue to work in the table, or you can double-click on the production version number 0002 and work in the detail screen to enter data, which might make data entry easier.

e)

Enter lot size 1 to 10 pc.

f)

In the Task List section, choose Routing from the list for Task List Type.

g)

Enter your routing's group number in the Group field. If you don't know the group number, you can find the correct routing by using the F4 search function or the drop-down list. Choose tab C: Search using material and choose Continue . Be sure to choose the routing with group counter 2.

h)

In the Bill of Materiall section, enter alternative BOM 1 and usage 1.

i)

Now you can close the detail screen by choosing

j)

Be sure to save your production versions.

b y

.

C S C

i n t e r n a l

u s e

b y

Choose Logistics → Production → Master Data → Production Versions or use transaction code C223.

u s e

a)

i n t e r n a l

C S C

Create another production version 0002 for the selection of BOMs and routings for T-B##. The production version should be valid from today until 12/31/9999, for lot sizes 1 to 10 pc. Use task list type routing with your routing for T-B## group counter 2, and use BOM alternative 1 with usage 1.

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Lesson: Modeling Alternative Manufacturing Processes

For the system to select your routings by production versions for this material, you will need to change the Selection Method field on the MRP4 view of the material master. a)

Choose Logistics → Production → Master Data → Material Master → Material → Change → Immediately or use transaction code MM02.

b)

Enter material T-B## and press ENTER.

c)

Select the MRP 4 view from the list and press ENTER.

d)

Enter plant 1000 and press ENTER.

e)

In the BOM explosion/dependent requirements section, change the Selection Method field to 2 Selection by production version or 3 Selection only by production version.

f)

Choose Save. Now the system will use the production versions for selection of the BOM and routing for this material.

F o r

o n l y

3.

b y

i n t e r n a l

u s e

u s e

b y

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i n t e r n a l

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Lesson Summary You should now be able to: • Model alternative manufacturing processes using alternative routings • Use production versions to model a very specific production process

o n l y

F o r

b y

i n t e r n a l

u s e

u s e

b y

C S C

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C S C

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Lesson: Reference Operation Sets

Lesson: Reference Operation Sets Lesson Overview In this lesson you will learn about reference operation sets and how to use them. You will create a reference operation set and reference it in your routing. You will also use a reference operation set as a template for creating routings.

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

o n l y

Utilize reference operation sets to minimize routing maintenance Create a reference operation set Use a reference operation set in a routing Use a reference operation set as a template to create a routing

F o r

• • • •

u s e

C S C

u s e

b y

The inspection process for several different pumps consists of the same steps. You need an efficient way to maintain these steps on multiple routings. Your group routing uses the same steps, but they have different standard values. You want to use these inspection steps as a template as an efficient way of creating your group routing.

Reference Operation Sets

b y

C S C

A reference operation set is a standard operation sequence for performing a task that is frequently used. Creating a reference operation set provides an efficient way to maintain this set of operations. It can be used either as a reference or as a template when you create a routing.

i n t e r n a l

i n t e r n a l

Business Example

F o r

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Figure 157: Reference Operation Sets

C S C

b y

u s e

C S C

i n t e r n a l

b y

A reference operation set can be created manually, or a routing or reference operation set can be used as a template. If you copy from a routing, only the basic sequence is copied. If you copy from a reference operation set, there is no reference.

u s e

A reference operation set does not allow parallel or alternative sequences. Material components, PRTs, and trigger points can be assigned to an operation in a reference operation set. Any assignments to a reference operation set will be copied into the routing. Any change made to a reference operation set will update all routings that use it.

i n t e r n a l

The reference to a reference operation set is created in the operation overview. The operations in the reference operation set are renumbered to fit into the routing.

F o r

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Lesson: Reference Operation Sets

Exercise 24: Reference Operation Sets Exercise Objectives After completing this exercise, you will be able to: • Create a reference operation set • Use a reference operation set in a routing • Use a reference operation set as a template to build a routing

Business Example

o n l y

C S C

Create a reference operation set for the inspection of manufacturing products.

Work Center

Control Key

Description

Labor

10

R-K##

PP01

Test Inspection

10 Min

20

R-P##

PP01

Examine after testing

5 Min

C S C

Operation

b y

i n t e r n a l

Create a reference operation set for the inspection of your manufacturing products. This will be an in-process inspection to be used for production with status Release (general). Assign it to your planner group 0##, use the description In-process inspection ##, and enter the data in the table below.

F o r

o n l y

Task 2: Assign the reference operation set to your routing. 1.

Change your routing for T-F## to include the reference operation set you just created. This inspection needs to take place just prior to final assembly, and again before delivery to stock.

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b y

1.

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Task 1:

F o r

In your production process, there is an inspection process that is common to many routings. Since the steps and standard values are identical for all routings, you need an efficient way to maintain this data. In your group routing, the steps are identical but the standard values are different. You need an efficient way to build these steps into your routing but still be able to change the standard times.

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Task 3: Use your reference operation set to build inspection steps into your group routing. 1.

Your group routing PUMP## also needs the same inspection steps, but since the standard values are different in this routing you will use the reference operation set to insert the operations and then unlock the reference so you can change the standard values for this routing. The reference operation set should be inserted at operations 35 and 45. Only unlock the reference at 35, since those are the only standard values that are different.

Task 4:

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b y

2.

Display your routing for T-F## and plant 1000 to make sure the changes were made.

3.

Display your group routing PUMP## to check if the changes have also been made there. Was the standard value for operation 45 changed? Was the standard value for operation 35 changed? Why or why not?

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i n t e r n a l

u s e

u s e

Change the standard value of operation 10 in your reference operation set from 10 min to 15 min and update all routings to which it is assigned. What does the warning message mean?

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1.

F o r

New inspection requirements have increased the standard time at inspection work center R-K## from 10 min to 15 min. Change your reference operation set to reflect this new time.

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Lesson: Reference Operation Sets

Solution 24: Reference Operation Sets Task 1: Create a reference operation set for the inspection of manufacturing products.

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Work Center

Control Key

Description

Labor

10

R-K##

PP01

Test Inspection

10 Min

20

R-P##

PP01

Examine after testing

5 Min

Choose Logistics → Production → Master Data → Routings → Routings → Reference Operation Sets → Create or use transaction code CA11.

b)

Choose Enter

c)

Enter the description In-process inspection ##, usage 1, status 4, planner group 0##, lot size 1 to 100000 pc, and choose the Operation overview icon .

d)

Enter the data from the table and save. Make note of the system assigned group number that appears in the status bar when you save.

without entering any data in the initial screen.

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a)

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Operation

i n t e r n a l

C S C

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Create a reference operation set for the inspection of your manufacturing products. This will be an in-process inspection to be used for production with status Release (general). Assign it to your planner group 0##, use the description In-process inspection ##, and enter the data in the table below.

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Task 2: Assign the reference operation set to your routing. Change your routing for T-F## to include the reference operation set you just created. This inspection needs to take place just prior to final assembly, and again before delivery to stock. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the operation overview, choose Extras → Reference → Create.

d)

Enter operation 25 and the group number of the reference operation set you recorded earlier. If you don't have the group number, you can search possible entries with the drop-down list. Choose S: Reference operation sets and enter your planner number 0##. Then choose Enter and your reference operation set will appear on a list for you to choose it.

e)

Repeat step d for operation 35.

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u s e

Use your reference operation set to build inspection steps into your group routing. Your group routing PUMP## also needs the same inspection steps, but since the standard values are different in this routing you will use the reference operation set to insert the operations and then unlock the reference so you

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1.

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Task 3:

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Note: Notice the operations of the reference operation set are display only and cannot be changed here. Changes will need to be made in the reference operation set. All routings to which it is assigned will then be automatically updated.

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b y

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Be sure the material number is blank, enter plant 1000, group PUMP##, and choose Enter .

c)

From the operation overview, choose Extras → Reference → Create.

d)

Enter operation 35 and the group number of the reference operation set you recorded earlier. If you don't have the group number, you can search possible entries with the drop-down list. Choose S: Reference operation sets and enter your planner number 0##. Then choose Enter and your reference operation set will appear on a list for you to select it.

e)

Repeat step d using operation 45.

f)

Select operation 35 and choose Extras → Reference → Unlock.

g)

Now change the standard times of operations 35 and 36 to 5 Min and 3 Min, respectively.

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Note: Be aware that since this reference has been unlocked, any changes to the reference operation set will not update operations 35 and 36.

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a)

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can change the standard values for this routing. The reference operation set should be inserted at operations 35 and 45. Only unlock the reference at 35, since those are the only standard values that are different.

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Task 4: New inspection requirements have increased the standard time at inspection work center R-K## from 10 min to 15 min. Change your reference operation set to reflect this new time.

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b y

u s e

Choose Logistics → Production → Master Data → Routings → Routings → Reference Operation Sets → Change or use transaction code CA12.

b)

Enter the group number of your reference operation set or search for it as previously indicated and choose Enter .

c)

Acknowledge the warning message that appears. This message means that upon saving, any changes made to the reference operation set will update all routings to which it is assigned.

d)

Double-click on operation number 10 to go to the details of the operation. Change the 10 Min of labor time to 15 Min.

e)

Save the reference operation set.

Display your routing for T-F## and plant 1000 to make sure the changes were made. Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

Double-click on operation number 25 and check the details to be sure the labor time is now 15 Min.

d)

Repeat this for operation number 35.

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a)

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.

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a)

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2.

Change the standard value of operation 10 in your reference operation set from 10 min to 15 min and update all routings to which it is assigned. What does the warning message mean?

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Lesson: Reference Operation Sets

Display your group routing PUMP## to check if the changes have also been made there. Was the standard value for operation 45 changed? Was the standard value for operation 35 changed? Why or why not? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03.

b)

Be sure the material number is blank, enter plant 1000, group PUMP##, and choose Enter .

c)

Double-click on operation number 45 and check the details to be sure the labor time is now 15 Min. Yes, this standard value was changed when the reference operation set was saved.

d)

Repeat this for operation number 35. No, the standard values here were not changed because the link back to the reference operation set was broken when it was unlocked.

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Lesson Summary You should now be able to: • Utilize reference operation sets to minimize routing maintenance • Create a reference operation set • Use a reference operation set in a routing • Use a reference operation set as a template to create a routing

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F o r

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Lesson: Lead Time Scheduling and Material Master Updates

Lesson: Lead Time Scheduling and Material Master Updates Lesson Overview This lesson describes the details of lead time scheduling and updating in-house production time in the material master.

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

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As a member of the project team, you are responsible for the precise time scheduling of your products. To ensure this can happen, you need to first fulfill the following prerequisites:

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Business Example

Lead Time Scheduling and Material Master Updates

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Material requirements planning explodes a material's BOM, generates planned orders or purchase requisitions for the components to be procured, and calculates basic order dates. Basic order dates (planned dates) are calculated using either the lot-size-independent or lot-size-dependent in-house production time for internally procured materials, or the planned delivery time for externally procured materials. The in-house production time for a material can be calculated using lead time scheduling of a routing without an order, and can then copied to the material master.

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Maintain working times Maintain in-house production time in the material master Prepare reduction measures

b y

• • •

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•

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• •

F o r

Describe in detail the concept of lead time scheduling and updating in-house production time in the material master Identify the data used in lead time scheduling Explain how the SAP ERP system uses the data to determine the lead time schedule Update the material master record of a material from the routing

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•

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Figure 158: Calculation of Basic Dates

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Production planning has two types of scheduling that are implemented in different ways: basic date scheduling and lead time scheduling.

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Figure 159: Scheduling in Production Planning

To ensure smooth material requirements planning, it is absolutely necessary to schedule a routing and to update the material master with the scheduling results. If material requirements planning (MRP) is carried out without lead time scheduling (as shown in the top half of the figure), capacity requirements are not determined for planned orders.

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Lesson: Lead Time Scheduling and Material Master Updates

Production orders are always scheduled using lead time scheduling for the operations. A production order always contains both sets of dates (basic dates and baseline dates). Baseline dates are relevant for production. You can also use lead time scheduling to determine capacity requirements for planned orders in MRP.

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You maintain the in-house production time in the material master. To calculate basic dates correctly in requirements planning, it is very important that the in-house production time in the material master agrees with the results of lead time scheduling in the routing.

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Figure 160: Scheduling of In-House Production Time

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PLM114

Lesson: Lead Time Scheduling and Material Master Updates

Exercise 25: Scheduling Exercise Objectives After completing this exercise, you will be able to: • Schedule a routing • Analyze the schedule of a routing using a table and Gantt chart • Update the basic dates in the material master from the schedule of the routing

Business Example

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C S C

b y

Schedule your routing to make sure the production schedule is accurate. Display the schedule using an object overview and a Gantt chart. Schedule your routing for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule.

Schedule your routing for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and update the material master record.

2.

Update the material master record with the schedule data.

3.

Now check the material master to be sure it was updated.

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F o r

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Schedule your routing and update the material master record with the schedule data.

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Task 2:

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1.

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Task 1:

F o r

It is important to ensure that the production schedule is accurate. Therefore, you need to analyze the scheduling of routings before they are used to create production order. In addition, to ensure that basic date and lead time scheduling are synchronized, you will need to schedule the routing and update the material master record.

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Solution 25: Scheduling Task 1: Schedule your routing to make sure the production schedule is accurate. Display the schedule using an object overview and a Gantt chart.

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b y

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today's date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

Make sure all your operations are scheduling correctly in the scheduling overview table that appears. Make any necessary corrections and schedule the routing again.

g)

Click the Gantt chart icon

.

b y

i n t e r n a l

u s e

and view the schedule graphically.

i n t e r n a l

u s e

Schedule your routing for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule.

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1.

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F o r

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Lesson: Lead Time Scheduling and Material Master Updates

Task 2: Schedule your routing and update the material master record with the schedule data.

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today's date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

In the Scheduling Overview, select the Scheduling Results icon

i n t e r n a l

C S C

Schedule your routing for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and update the material master record.

F o r

o n l y

1.

.

b y

. In the dialog box that appears, you can compare the scheduling results with the current material master settings. Choose the Update mat. master button

i n t e r n a l

a)

Choose Logistics → Production → Master Data → Routings → Extras → Material Master → Update Material Master or use transaction code CA96.

b)

Enter plant 1000, production planner 0##, and choose Enter

c)

Select your material from the list and choose the Update mat. master icon

.

on the tool bar.

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F o r

Update the material master record with the schedule data.

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2.

You should receive a message box that says “Scheduling data marked for material master update.”

b y

h)

in the dialog box.

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Now check the material master to be sure it was updated. a)

Choose Logistics → Production → Master Data → Material Master → Material → Display → Display Current or use transaction code MM03.

b)

Enter material T-F## and choose Enter

c)

Select the Work Scheduling view and choose

d)

Enter plant 1000 and choose

e)

You should see the results of the update in the In-house production time in days section.

. .

.

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F o r

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Lesson: Lead Time Scheduling and Material Master Updates

Lesson Summary You should now be able to: • Describe in detail the concept of lead time scheduling and updating in-house production time in the material master • Identify the data used in lead time scheduling • Explain how the SAP ERP system uses the data to determine the lead time schedule • Update the material master record of a material from the routing

o n l y

F o r

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Lesson: Time Components, Reduction Possibilities in the Routing Lesson Overview In this lesson you will look at the various options for detailed scheduling including interoperations times, continuous input/ouput, and splitting operations in multiple capacity work centers.

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

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Business Example

b y

u s e

i n t e r n a l

F o r

Float before production The float before production has the following two functions in the order: It can compensate for delays in the staging of the material components or if there is a capacity bottleneck at the work centers involved, you can move the production dates forward in the future. In this way it serves as a float for capacity leveling. The system calculates the scheduled start by adding the float before production to the basic start date.

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The two float times serve different purposes:

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Since malfunctions and other disturbances in the production process can never be fully prevented, the system carries out scheduling using a float before and a float after production. The floats before and after production are defined in the material master record using a scheduling margin key.

b y

Modeling Standard Float Time in the Routing

u s e

As a member of the project team, you are responsible for the precise time scheduling of your products. In order to do this you need to model the critical path and any possible interoperation or float time that might occur during a normal production. To ensure this can happen, you need to review the use of interoperation times, overlapping, and splitting in the routing operations.

i n t e r n a l

• •

Demonstrate the use of interoperation times in the routing for job shop related environments Demonstrate the use of Overlapping for a continuous manufacturing process Demonstrate the use of splitting for multi-capacity work centers.

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Lesson: Time Components, Reduction Possibilities in the Routing

Float after production The float after production is used in the order to compensate for unexpected interruptions in the production process. It prevents a delay of the scheduled finish. The system calculates the scheduled finish by subtracting the float after production from the basic finish date.

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Figure 161: Time Elements in Lead Time Scheduling

i n t e r n a l

F o r

Queue time Setup time Processing time Teardown time Process-related wait time

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• • • • •

Queue Time In addition to the floats before and after production, you can define an operation float in the form of a queue time. The queue time is used to compensate for malfunctions and delays within an operation. The queue time is the interval between the earliest and latest dates of the operation (see the following figure). During each scheduling run, the system calculates the earliest and the latest dates for the individual operation segments. You can maintain the queue time in both the work center and operation. However, the system only schedules with the

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C S C

The duration of an operation consists of a maximum of five time components:

b y

The order float can be predefined and is controlled by the scheduling margin key. In Customizing, the scheduling margin key is defined and then assigned on the MRP 2 view of the material master record.

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queue time in the work center if you have not maintained the queue time in the operation. If the lead time of an operation must be reduced, the system can shorten the standard queue time as far as the minimum queue time. Setup Time The setup time is the time needed to prepare the work center for operations to perform there. The setup time is part of the lead-time. Processing Time The processing time is the time needed to process a material in an operation. The processing time is dependent on the order quantity, and does not contain a setup or teardown time. It is part of the execution time.

Wait Time

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C S C

The teardown time is the time needed to restore a work center to its normal state after operations have been processed. The teardown time is part of the execution time.

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Teardown Time

b y

Maximum Minimum

In scheduling, only the minimum wait time is taken into account. The maximum wait time is used for information.

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F o r

In addition to these operation segments, you can define a move time. The move time is the time needed to move a material from one work center to the next one. Move time is always between two operations and is assigned to the preceding operation. You can maintain the move time in the individual operations or in Customizing per location group in the move time matrix. In the interoperation times section of the Operation Details screen, you can maintain a minimum and a standard move time. If reduction measures are carried out, the system schedules the operations

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Move Time

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The wait time is scheduled without taking the factory calendar into account. This means that it can be scheduled daily from 0.00 to 24.00.

b y

Using the teardown/wait simul. indicator in the interoperation times section of the Operation Details screen, you can specify whether teardown and wait are to be considered as simultaneous or consecutive operation segments in scheduling. If teardown and wait times are simultaneous, the lead time of the operation is reduced

u s e

• •

u s e

The wait time is the time between the end of the execution time and the start of move time. In the SAP system, types of wait time are:

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Lesson: Time Components, Reduction Possibilities in the Routing

using the minimum move time. The system determines the move time using the move time matrix, only if you do not maintain move times in the interoperation times section of the Operation Details screen. You can combine work centers which are in close proximity to each other into location groups. You can define location groups in Customizing and assign a work center to a location group on the Scheduling screen of the work center. In the move time matrix, you can specify planned values for the move time within a location group or from one location group to another. For each entry, you can specify a minimum and a standard move time. The operation segments and the move time are used to determine the execution time, lead time and interoperation time of an operation.

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The capacity requirement can be displayed on the earliest or latest start date depending on the customizing settings.

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For external operations, the delivery time is specified in days. These operations are scheduled based on the Gregorian calendar.

F o r

The material requirement is scheduled from the earliest start date (you can change this in Customizing).

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Figure 162: Time Components and Their Origins

You maintain time elements for lead time scheduling in various places within the PP application. It is important to make the correct settings and use the system properly for successful scheduling.

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The interoperation time in the material master is calculated from: • • • •

Order float (float before and after production) Operation float (queue time) Wait time Move time

Modeling Operation Splits in the Routing

To reduce the lead time of a routing or production order you can overlap operations. This means that an operation starts before the previous operation has finished

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Modeling Continuous Manufacturing as with Multiple Operations

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An operation is split if it is carried out on several machines or by several persons at the same time. Splitting an operation has the following effects on the operation dates: The processing time/execution time becomes shorter. Setup and teardown must be carried out more than once for the operation.

b y

You can define for each individual operation whether it should overlap with the next consecutive operation and in what way. To do this you can set the following indicators:

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Required overlapping

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•

This means the operations always overlap Optional overlapping

•

Flow manufacturing

F o r

For every type of overlapping you can • •

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Define a minimum overlap time which only allows overlapping after a particular minimum limit has been reached. Define a minimum send-ahead quantity to ensure that the operation is performed for a particular minimum quantity of the material to be produced, before the next operation starts.

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o n l y

This means the system extends the lead time of all operations, that overlap using flow manufacturing, to the same length as the lead time of the longest of these operations. As with required overlapping, the operations always overlap

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This means the operations overlap if scheduling uses a reduction level that allows overlapping

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Lesson: Time Components, Reduction Possibilities in the Routing

Reduction Measures The system can carry out reduction measures in lead time scheduling for orders. If the lead time calculated in scheduling is longer than the time between the basic dates, the system will carry out reduction measures to reduce the lead time. Reduction is carried out step by step. After each reduction measure, the system checks whether the calculated dates are within the basic dates. If this is the case, no further reduction measures are carried out.

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The order is rescheduled after every reduction level. To improve performance it is recommended that you keep the number of reduction steps to a minimum.

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You can assign a reduction strategy to each operation in the interoperation times section of the Operation Details screen. This strategy specifies how many reduction levels may be applied to an operation (maximum of six levels) which reduction measures are carried out at the individual levels.

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Figure 163: Reduction Process in Scheduling Routings

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Figure 164: Reduction Strategy

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The following reduction measures can be carried out with respect to the operation: Reduction of the queue time:

•

F o r

You can also specify reduction for the floats before and after production in the order or in Customizing for each plant, order type and planner group. In order to reduce the lead time of a routing with parallel sequences, you specify that reduction is only carried out on operations, if a reduction in their execution time leads to a reduction in the overall lead time of the order. The sequence of such operations in the routing with parallel sequences forms the "critical path". If applying reduction measures to an operation, would not lead to an overall lead time reduction, this operation is not reduced. If a routing does not contain parallel sequences, there is no critical path. All operations are then reduced, irrespective of whether you have selected reduction via the critical path or not.

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•

For each reduction level, you can specify the percentage by which the queue time is to be reduced. However, you cannot reduce to a value smaller than the minimum queue time. Reduction of the execution time by splitting - Dividing an operation between several people or machines results in a reduction of the execution time. Reduction of the lead time by overlapping - You can reduce the overall lead time of an order by overlapping operation processing. Reduction of the move time - You can reduce the standard move time as far as the minimum move time. The minimum wait time cannot be reduced.

u s e

u s e

•

i n t e r n a l

You can set the time elements that can be reduced as well as the reduction strategy in Customizing (for each order category and planner group).

PLM114

Lesson: Time Components, Reduction Possibilities in the Routing

Exercise 26: Time Elements of the Operation in Scheduling Exercise Objectives After completing this exercise, you will be able to: • Create an operation in a routing that splits the workload over several machines • Create operations that model continuous output and overlap the previous operation to reduce lead time

C S C

Task 1:

i n t e r n a l

3.

Schedule your routing again for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. Compare the differences in scheduling. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

F o r

Operation 20 in your routing, preassembly of the pump, has a work center with three machines (three individual capacities). Change this operation to require splitting across all three machines.

Task 2: Due to a lean manufacturing initiative in your company, you are required to use single-piece manufacturing. Change your routing to accommodate this requirement. 1.

Change your routing so every operation requires overlapping with one piece send-ahead quantity. Continued on next page

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457

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2.

C S C

Schedule your routing for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

b y

1.

u s e

u s e

b y

Change the operation on your routing to require splitting the workload across all machines.

i n t e r n a l

One operation in your routing to produce pumps has several machines that can do the work. You need to be sure the routing will schedule the workload across all machines. As part of a lean manufacturing initiative at your company, you are required to perform single-piece production.

F o r

o n l y

Business Example

Unit 8: Advanced Routing Functions

2.

PLM114

Schedule your routing again for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. Compare the differences in scheduling. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

o n l y

F o r

b y

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b y

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PLM114

Lesson: Time Components, Reduction Possibilities in the Routing

Solution 26: Time Elements of the Operation in Scheduling Task 1: Change the operation on your routing to require splitting the workload across all machines.

C S C

b y

u s e

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today's date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

The processing time (labeled Edit) for operation 20 is 1000 min.

g)

In the Scheduling Overview, select the Scheduling Results icon

.

. Make note of the lead time in days for the entire h)

Click the Gantt chart icon

C S C

routing.

b y

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

u s e

a)

i n t e r n a l

i n t e r n a l

Schedule your routing for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

F o r

o n l y

1.

and view the schedule graphically.

F o r

o n l y

Continued on next page

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Unit 8: Advanced Routing Functions

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

Double-click on operation number 20 to go to the details of the operation.

d)

Scroll down to the splitting section and select the indicator for Required splitting. You need not enter the number of splits, but let it default to the number of individual capacities.

Schedule your routing again for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. Compare the differences in scheduling. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today's date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

The processing time (labeled Edit) for operation 20 is 333.3 min.

g)

In the Scheduling Overview, select the Scheduling Results icon

i n t e r n a l

u s e

b y

Enter material T-F##, plant 1000, and choose Enter

.

. Make note of the lead time in days for the entire routing. h)

Click the Gantt chart icon

and view the schedule graphically.

Continued on next page

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b)

C S C

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b y

a)

u s e

F o r

.

i n t e r n a l

C S C

3.

Operation 20 in your routing, preassembly of the pump, has a work center with three machines (three individual capacities). Change this operation to require splitting across all three machines.

F o r

o n l y

2.

PLM114

PLM114

Lesson: Time Components, Reduction Possibilities in the Routing

Task 2: Due to a lean manufacturing initiative in your company, you are required to use single-piece manufacturing. Change your routing to accommodate this requirement.

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

Select all operations and choose Details → Operations to go to the details of the operation.

d)

Scroll down to the overlapping section, select Required overlapping, and enter 1 pc in the min. send-ahead qty.

e)

to go to the next operation and repeat the settings until all Choose operations have been performed.

f)

Click the green back arrow

to get back to the operations overview

and then choose the Sequence overview icon the other sequences.

u s e

Scroll down to the overlapping section, select Required overlapping, and enter 1 pc in the min. send-ahead qty.

j)

to go to the next operation and repeat the settings until all Choose operations have been performed.

k)

Save your changes.

Continued on next page

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461

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i)

.

C S C

Select all operations and choose Details → Operations to go to the details of the operation.

overview icon

b y

h)

Select sequence 1, the parallel sequence, and choose the Operations

u s e

g)

i n t e r n a l

to see

F o r

b y

.

i n t e r n a l

C S C

Change your routing so every operation requires overlapping with one piece send-ahead quantity.

F o r

o n l y

1.

Unit 8: Advanced Routing Functions

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today's date as the start date, select Forward as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

In the Scheduling Overview, select the Scheduling Results icon . Make note of the lead time in days for the entire routing.

g)

Choose the Gantt chart icon

.

b y

i n t e r n a l

u s e

u s e

b y

and view the schedule graphically.

i n t e r n a l

C S C

Schedule your routing again for the pump T-F## using forward scheduling from today's date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. Compare the differences in scheduling. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

F o r

o n l y

2.

PLM114

C S C

F o r

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462

© 2006 SAP AG. All rights reserved.

2006/Q2

PLM114

Lesson: Time Components, Reduction Possibilities in the Routing

Lesson Summary You should now be able to: • Demonstrate the use of interoperation times in the routing for job shop related environments • Demonstrate the use of Overlapping for a continuous manufacturing process • Demonstrate the use of splitting for multi-capacity work centers.

Related Information •

[Enter an optional reference using the URL or CrossReference tag to additional information that learner may find useful. Examples include websites or whitepapers. Delete if not used.]

o n l y

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Unit 8: Advanced Routing Functions

PLM114

Lesson: Trigger Points in the Routing Lesson Overview In this lesson you will learn how trigger points can be used to trigger actions in the production order. You will use a standard trigger point to create a specific trigger point for your routing.

Lesson Objectives After completing this lesson, you will be able to: Describe the use of trigger points to streamline and automate several administrative processes

F o r

o n l y

•

Business Example

C S C

b y

u s e

u s e

b y

i n t e r n a l

i n t e r n a l

As a production planner/scheduler, you are responsible for modeling the production process of several materials in SAP ERP. Several of your assembles undergo a very sophisticated manufacturing process. Due to the complex nature of the process, it often yields product that needs to be reworked during the process, as well as after the final process is complete. Your company has asked you to find a way to automate the rework business process at the time rework is reported during production confirmation. You need to investigate trigger points as a way of automating the rework process.

C S C

F o r

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2006/Q2

PLM114

Lesson: Trigger Points in the Routing

Defining Trigger Points Trigger points are assigned to operations in a routing to trigger certain functions in the production order at a later time. Trigger points can trigger functions when an operation’s status changes or when an operation is confirmed. The person making the confirmation decides if the function is triggered when the operation is confirmed. Trigger points can trigger the following functions: • •

•

C S C

•

C S C

b y

u s e

i n t e r n a l

b y

You can combine several standard trigger points into a trigger point group. If you copy from a trigger point group, the system automatically transfers all standard trigger points in the trigger point group to the operation. Using trigger point groups considerably reduces the time and work involved in creating trigger points. You can maintain trigger point groups in Customizing.

u s e

Standard trigger points can be copied to create new trigger points. If you copy a standard trigger point to create a trigger point, the system automatically transfers all necessary data from the standard trigger point into the trigger point you are creating. This reduces the time and work involved in creating a trigger point.

i n t e r n a l

•

F o r

o n l y

•

Release succeeding operations. You can release all operations that follow the operation which has the trigger point assigned to it. Release up to stop indicator. You can release all operations up to and including the next operation for which the RelStop indicator is set. Release preceding operations. You can release all operations before the operation with the trigger point assigned to it. Create order by copying. You can create a new order without reference to a material by copying a reference operation set. Insert reference operation set. You can insert a reference operation set into an existing order. To do this, you must enter the operations between which you would like to insert the reference operation set. Start workflow task (for example, send mail to a user)

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Setting Up a Trigger Point 1.

Choose Logistics → Production → Master Data → Standard Trigger Points → Standard trigger pt → Create or use transaction CO31.

2.

Enter the Std Triggerpoint name and description.

3.

Assign a usage and group if you want.

4.

In Usage, select the function the trigger point should serve: TrigPointFuncts or Release Stop. •

o n l y

C S C

b y

6.

Select the function the trigger point should execute, along with the system or user status and how it is initiated.

7.

In trigger point parameters, assign the group number and counter or any additional data that is needed.

b y

i n t e r n a l

u s e

u s e

Assign a User Status profile and press ENTER.

i n t e r n a l

5.

F o r

•

TrigPointFuncts: The trigger point triggers the functions you entered on the detail screen for trigger points (for example, release operation or include reference operation set). Release Stop: The operation is the last in a series of operations released by the trigger point. If the function release up to stop was triggered in a previous operation, all subsequent operations are released up to the operation with the RelStop indicator

C S C

F o r

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2006/Q2

PLM114

Lesson: Trigger Points in the Routing

Lesson Summary You should now be able to: • Describe the use of trigger points to streamline and automate several administrative processes

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F o r

b y

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b y

C S C

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C S C

F o r

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467

Unit 8: Advanced Routing Functions

PLM114

Lesson: Scrap and Its Effects Lesson Overview In this lesson you will look at the different ways to define scrap in the SAP ERP system, and what effect they have on planning.

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

Business Example

b y

u s e

F o r

468

Assembly scrap Component scrap Operation scrap

© 2006 SAP AG. All rights reserved.

2006/Q2

o n l y

You can calculate and plan the scrap quantity that will result from production. These scrap quantities are then included in the planning run and in the calculation of production costs. Which calculation the system uses depends on the settings in the material master record, the BOM, or the routing. The scrap quantity is settled against the net requirements quantity. Scrap is used for material requirements planning and product costing. The three scrap calculation procedures supported by the system are:

C S C

i n t e r n a l

b y

Calculating Scrap

• • •

u s e

As a production planner/scheduler you are responsible for meeting customer services demands placed on you by the forecast and sales orders. Several of the production processes that you are responsible for scheduling are quite complex and yield loss is quite high. To assure that you deliver enough good production to inventory, you need to factor in these losses ahead of time. You want to examine the options in the bill of material, the material master, and the routing so you can properly model your scrap allowances.

i n t e r n a l

C S C

•

F o r

o n l y

•

Explain how the assembly and component scrap in the material master field affect the production process Explain how the component scrap and operation scrap percentage in the bill of material affect the production process Explain how the scrap in the percentage field in the routing affects the production confirmation process

PLM114

Lesson: Scrap and Its Effects

o n l y

F o r

C S C

Assembly Scrap

Component Scrap

o n l y

b y

u s e

i n t e r n a l

C S C

F o r

b y

Assembly scrap is only used when the material is an assembly. Reasons for assembly scrap include inadequate quality or bad working conditions, such as heat, cold, or dampness.

You use this function to plan the scrap of a component that may break during production of an assembly. You can define component scrap in two places: • •

2006/Q2

u s e

You use this function to plan the scrap that results from the production of an assembly. Assembly scrap increases the order quantity of the assembly and, subsequently, increases the order quantity for each component in the BOM of the assembly by adjusting the quantity of the dependent requirements generated during the MRP run. The system automatically increases the quantity to be produced by the percentage of scrap. However, the system always uses the estimated yield for the availability calculation for the assembly. Furthermore, the estimated yield of the assembly is always displayed in the MRP list or in the stock/requirements list.

i n t e r n a l

Figure 165: Scrap Categories and Their Effect

In the BOM on the Item Detail Screen: General Data (quantity data section). This component scrap is only relevant for the individual BOM. In the material master (MRP 4 view) in the Component scrap field. This component scrap is relevant for all BOMs.

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The component scrap quantity maintained for a material component in the BOM has the higher priority. Component scrap increases the dependent requirements quantity of the component. If a scrap quantity is planned for a higher-level assembly, assembly scrap and component scrap are both added to the component level. Component scrap relates only to the individual components in an assembly. During BOM explosion, the system increases only the component quantity by the calculated scrap quantity.

Operation Scrap

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b y

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F o r

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© 2006 SAP AG. All rights reserved.

C S C

470

b y

Operation scrap in the operation results in a fall in quantity in the next operation, and is taken into consideration in scheduling and costing. The scrap percentage maintained in the operations is added to the material master with the scheduling update.

u s e

Operation scrap in the BOM relates to the quantity of a component to be processed in an assembly. The specification replaces the estimated assembly scrap for the high quality materials and allows for more precise MRP. The net indicator controls the operation scrap for components and is calculated without taking into account the assembly scrap (net input quantity). You still have to set this indicator if no operation scrap has been maintained and the assembly scrap is not to be taken into account.

i n t e r n a l

If the component is contained in an assembly for which an assembly scrap quantity has been maintained, the system only takes the operation scrap into account. The net indicator instructs the system to calculate the component operation scrap without taking assembly scrap into account (net usage scrap). You should also set the net indicator if operation scrap has not been maintained and assembly scrap has been entered. The assembly scrap should not, however, be taken into account.

F o r

Before high-value components are built into an assembly, your manufacturing process may require a quality control check of the assembly. Faulty materials that were taken into account in assembly scrap are not passed on to the next operation; they are removed from the manufacturing process. Therefore, for a high-value component, you plan using operation scrap instead of general assembly scrap. This scrap quantity refers to the quantity of one component that is to be processed in an operation, meaning that the planning run is more exact and you can determine service and quantity consumption more precisely.

PLM114

Lesson: Scrap and Its Effects

Scrap Example

b y

u s e

i n t e r n a l

Start Qty

Scrap Qty

Op Yield

10

5%

100

5

95

20

5%

95

4.75

90.25

C S C

Scrap

Material

Req Op

Asmbly Scrap

Comp Scrap

BOM Scrap

Op Net Ind

Req Qty

Blank

10

12%

2%

0%

N

115

Gasket

30

12%

3%

0%

Y

103

Screws

30

12%

7%

0%

Y

107

F o r

Execution time is also adjusted for the scrap quantities.

© 2006 SAP AG. All rights reserved.

471

o n l y

Based on the component scrap and operation scrap values defined on the BOM and routing, the system calculates the following planned component and production quantities:

2006/Q2

b y

Operation

u s e

Assembly scrap in the material master can be calculated from operation scrap entered in the routing. The following example shows how the assembly scrap is calculated. Formula: total scrap quantity (9.75) divided by total yield quantity (90.25) equals 10.80%. Even though the unit of measure is pc, there is no rounding in the scrap calculation.

i n t e r n a l

C S C

o n l y

F o r

Figure 166: Scrap Example

Unit 8: Advanced Routing Functions

PLM114

Operation

Production Qty

Time Target Required Time

10

112

10 H

11.2 H

20

106

10 H

10.6 H

30

101

5H

20.2 H

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b y

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C S C

F o r

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2006/Q2

PLM114

Lesson: Scrap and Its Effects

Exercise 27: Scrap in Production Exercise Objectives After completing this exercise, you will be able to: • Maintain scrap in the material master, BOM, and routing • Maintain and use assembly scrap, component scrap, and operation scrap • Use the operation net indicator in planning scrap • Use operation scrap in the routing to update assembly scrap in the material master

Business Example

o n l y

C S C

b y

u s e

1.

Change the material master of your pump R-B1## to plan for 12% assembly scrap.

2.

Change the material masters of your pump components R-T1##, R-T2##, and R-T3## to plan for 2%, 3%, and 7% component scrap, respectively.

b y

3.

Change the BOM of your pump R-B1## so planning does not plan for both operation and assembly scrap by setting the operation net indicator for R-T2## and R-T3##.

C S C

4.

Change your routing for the production of material R-B1## in plant 1000 to reflect the operation scrap of 5% that occurs at operations 10 and 20. Also, adjust the standard values of the first three operations to match the data in the table below.

o n l y

F o r

i n t e r n a l

Maintain assembly scrap, component scrap, and operation scrap in your pump production.

u s e

i n t e r n a l

Task 1:

F o r

Your production for the pump casing creates scrap in several different areas. You need to use assembly scrap, component scrap, and operation scrap to accurately plan the required quantities. You also want to use the operations scrap in the routing to update the assembly scrap in the material master without planning scrap for both.

Standard Processing Times: Activity

Op 10

Op 20

Op 30

Base Quantity

10 PC

10 PC

5 PC

Setup

10 Min

3 Min

0 Min

Continued on next page

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Unit 8: Advanced Routing Functions

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Machine

60 Min

60 Min

60 Min

Labor

60 Min

60 Min

60 Min

Scrap in %

5

5

0

Task 2: Test the scrap calculation by scheduling a production order for material. 1.

Schedule a production order for 100 pieces of R-B1## due in two months.

2.

Analyze the component quantities and operation times to be sure the system planned properly for scrap.

o n l y

Update the material master record with the operation scrap from the routing.

b y

i n t e r n a l

u s e

u s e

b y

Update the material master record of R-B1## with the operation scrap from the routing.

i n t e r n a l

C S C

1.

F o r

Task 3:

C S C

F o r

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2006/Q2

PLM114

Lesson: Scrap and Its Effects

Solution 27: Scrap in Production Task 1: Maintain assembly scrap, component scrap, and operation scrap in your pump production.

C S C

b y

u s e

Choose Logistics → Production → Master Data → Material Master → Material → Change → Immediately or use transaction code MM02.

b)

Enter R-B1## for the material number, choose the MRP1 and MRP3 views, and enter plant 1000.

c)

In the section for Lot Size Data, enter 12 in the Assembly scrap (%) field. On the MRP3 view be sure the Strategy Group is set to 40 and save.

Change the material masters of your pump components R-T1##, R-T2##, and R-T3## to plan for 2%, 3%, and 7% component scrap, respectively. Choose Logistics → Production → Master Data → Material Master → Material → Change → Immediately or use transaction code MM02.

b)

Enter R-T1## for the material number, choose the MRP4 view, and enter plant 1000.

c)

In the section for BOM explosion/dependent requirements data, enter 2 in the Component scrap (%) field and save.

d)

Repeat steps b through c for each of the other materials, R-T2## and R-T3##, and enter the correct scrap quantity for each.

b y

a)

u s e

C S C

i n t e r n a l

a)

i n t e r n a l

2.

Change the material master of your pump R-B1## to plan for 12% assembly scrap.

F o r

o n l y

1.

F o r

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Continued on next page

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Unit 8: Advanced Routing Functions

a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change or use transaction code CS02.

b)

Enter material R-B1##, plant 1000, BOM usage 1, and choose Enter.

c)

In the General Item Overview, select components R-T2## and R-T3##.

d)

Go to the Item details screen by choosing the Item icon

e)

In the Item details screen, select the Net ID for R-T2##.

f)

Choose Next

g)

Select the Net ID and save your BOM.

.

to move to the details of R-T3##.

Change your routing for the production of material R-B1## in plant 1000 to reflect the operation scrap of 5% that occurs at operations 10 and 20. Also, adjust the standard values of the first three operations to match the data in the table below.

i n t e r n a l

Op 30

Base Quantity

10 PC

10 PC

5 PC

Setup

10 Min

3 Min

0 Min

Machine

60 Min

60 Min

60 Min

Labor

60 Min

60 Min

60 Min

Scrap in %

5

5

0

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter the material R-B1## and plant 1000 and choose Enter

c)

Select operations 10, 20, and 30 and choose Details → Operation from the menu. Enter the base quantity and the standard operation processing times from the table. Scroll down to enter the scrap values to navigate to the next operation detail screen. Continue and choose until all times and scrap quantities have been entered and then choose to return to the operation overview. Be sure you save your routing.

.

Continued on next page

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F o r

Op 20

C S C

Op 10

b y

Activity

u s e

u s e

b y

Standard Processing Times:

i n t e r n a l

C S C

4.

Change the BOM of your pump R-B1## so planning does not plan for both operation and assembly scrap by setting the operation net indicator for R-T2## and R-T3##.

F o r

o n l y

3.

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PLM114

Lesson: Scrap and Its Effects

Task 2: Test the scrap calculation by scheduling a production order for material. 1.

o n l y

Choose Logistics → Production → Production Control → Order → Create → With Material or use transaction code CO01.

b)

Enter material R-B1##, production plant 1000, and order type PP01 and choose Enter.

c)

Enter Total Qty of 100, a Basic Finish date 2 months from today and hit ENTER.

d)

Stay in the production order without saving.

Analyze the component quantities and operation times to be sure the system planned properly for scrap. In the production order, choose Component overview .

b)

You should see in the component overview that the system has planned the following: Reqmts qty

R-T1##

115

R-T2##

103

R-T3##

856

d)

Select operations 10, 20, and 30 and select the Op. details icon the lower left of the screen.

e)

Select the Qty/activities tab and compare the data to the table below.

f)

.

Operation

Operation Qty

To confirm time

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Choose Operations overview

When you are finished and are satisfied the production order was scheduled correctly, exit without saving by choosing and answering No to the dialog box.

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c)

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Component

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Schedule a production order for 100 pieces of R-B1## due in two months.

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Task 3: Update the material master record with the operation scrap from the routing.

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material R-B1##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today's date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

In the Scheduling Overview, select the Scheduling Results icon .

g)

In the dialog box that appears, you can compare the scheduling results with the current material master settings. Choose Update mat. master

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a)

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Choose Logistics → Production → Master Data → Routings → Extras → Material Master → Update Material Master or use transaction code CA96.

j)

Enter plant 1000, production planner 0##, and choose Enter

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Select your material from the list and be sure to select the Update with assembly scrap indicator. Now choose Update mat. master

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on the tool bar and check your material master record to be sure it updated correctly.

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You should receive a message box that says, “Scheduling data marked for material master update.” Choose OK and back out of the routing.

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in the dialog box.

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Update the material master record of R-B1## with the operation scrap from the routing.

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PLM114

Lesson: Scrap and Its Effects

Lesson Summary You should now be able to: • Explain how the assembly and component scrap in the material master field affect the production process • Explain how the component scrap and operation scrap percentage in the bill of material affect the production process • Explain how the scrap in the percentage field in the routing affects the production confirmation process

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Lesson: Production Resources/Tools Lesson Overview This lesson explains how to create and use production resources/tools.

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

Describe and use production resources/tools in the routing

Business Example

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The input screen for production resources/tools with a material master is automatically displayed when assigning a PRT to an operation. The PRT category can be changed.

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The PRT must be identified by a material master, equipment master, or a PRT master.

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Production resources/tools are required for production but are not consumed. A PRT may be needed in order to carry out an operation and therefore must be assigned to that operation.

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Production Resources/Tools

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As a production scheduler, several of your products require extensive testing. The testing process requires expensive and sophisticated equipment. For the purpose of informing the quality department of its need and duration of use, you think it might be useful to model in on the production floor. In order to do this you will use production resources/tools in the routing

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Figure 167: Production Resources/Tools

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Lesson: Production Resources/Tools

The ECC System differentiates between the following types of production resources/tools, according to their properties and business function: • • •

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In the SAP system, you can assign various PRT categories to an operation in a routing or a production order. The PRT category is determined by the requirements of a PRT and its reference to a particular object (material, equipment, and so on).

F o r

Production resources/tools can be assigned to operations, activities or phases in task lists (including standard networks and recipes), production orders and maintenance orders as well as networks. Production resources/tools that are used for testing during production, can be assigned to the corresponding inspection characteristic in the inspection plan.

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•

Materials that are accounted for in materials management, for instance in inventory management, requirements planning and procurement. Equipment, for instance measuring instruments or valuable tool, which are serviced Documents, for instance drawings or programs, which use the document management system. Miscellaneous production resources/tools (with a PRT master record), that require less maintenance in the system.

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Figure 168: PRT Categories

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PLM114

Lesson: Production Resources/Tools

Exercise 28: Creating and Assigning PRTs Exercise Objectives After completing this exercise, you will be able to: • Create a PRT • Assign a PRT to an operation on a routing

Business Example

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In your production process, you have production inspection tools that are needed for testing pumps. You need to create these as PRTs and assign them to your inspection operations on the routing.

Task 1:

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Create a miscellaneous PRT called INSP-## to represent your inspection gauge. Be sure you release it for use in production, allow it to be used only for routings, and the unit of measure is pieces.

Task 2:

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Display your routing for T-F## and plant 1000 to ensure the PRT is visible there also.

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Assign a PRT inspection gauge to operation 10 of your reference operation set.

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Assign a PRT to your inspection operation of your reference operation set.

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Create a PRT to represent your inspection gauge.

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Solution 28: Creating and Assigning PRTs Task 1: Create a PRT to represent your inspection gauge.

Enter INSP-## and press ENTER.

c)

Enter Inspection Gauge ## as the description, Status 03, Task List Usage 001, and Base Unit of Measure PC.

d)

Choose the Default icon to go to the default view.

e)

Enter Control Key 1 for all business processes, Ref. start date as 04 Start Date for execution, and Ref. date for finish as 05 Start date for wait.

f)

Save your PRT.

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Choose Logistics → Production → Master Data → Production Resources and Tools → Production Resources/Tools → PRT Master (Misc.) → Create or use transaction code CF01.

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Create a miscellaneous PRT called INSP-## to represent your inspection gauge. Be sure you release it for use in production, allow it to be used only for routings, and the unit of measure is pieces.

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Continued on next page

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Lesson: Production Resources/Tools

Task 2: Assign a PRT to your inspection operation of your reference operation set.

Choose Logistics → Production → Master Data → Routings → Routings → Reference Operation Sets → Change or use transaction code CA12.

b)

Enter the group number of your reference operation set or search for it as previously indicated and choose Enter .

c)

Acknowledge the warning message that appears. This message means that upon saving, any changes made to the reference operation set will update all routings to which it is assigned.

d)

Select operation 10 and choose Prod.resources/tools

e)

The dialog box that appears defaults to material PRT. If you want to assign a different PRT, you must choose the appropriate button at the bottom of the box. Choose Others to assign a miscellaneous PRT.

f)

Enter INSP-## as the name of the Prod.resource/tool and press ENTER. Respond to any messages that appear.

g)

Save the reference operation set.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

In the operations overview, be sure the PRT column is selected for both operations 25 and 35.

d)

Select one of those operations and choose Prod.resources/tools

.

. e)

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The PRT INSP-## should be visible.

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Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03.

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a)

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Display your routing for T-F## and plant 1000 to ensure the PRT is visible there also.

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2.

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b y

a)

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Assign a PRT inspection gauge to operation 10 of your reference operation set.

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Unit 8: Advanced Routing Functions

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Lesson Summary You should now be able to: • Describe and use production resources/tools in the routing

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Unit Summary

Unit Summary

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2006/Q2

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You should now be able to: • Use parallel sequences in modeling complex manufacturing processes • Use alternative sequences in modeling flexible manufacturing processes • Model alternative manufacturing processes using alternative routings • Use production versions to model a very specific production process • Utilize reference operation sets to minimize routing maintenance • Create a reference operation set • Use a reference operation set in a routing • Use a reference operation set as a template to create a routing • Describe in detail the concept of lead time scheduling and updating in-house production time in the material master • Identify the data used in lead time scheduling • Explain how the SAP ERP system uses the data to determine the lead time schedule • Update the material master record of a material from the routing • Demonstrate the use of interoperation times in the routing for job shop related environments • Demonstrate the use of Overlapping for a continuous manufacturing process • Demonstrate the use of splitting for multi-capacity work centers. • Describe the use of trigger points to streamline and automate several administrative processes • Explain how the assembly and component scrap in the material master field affect the production process • Explain how the component scrap and operation scrap percentage in the bill of material affect the production process • Explain how the scrap in the percentage field in the routing affects the production confirmation process • Describe and use production resources/tools in the routing

Unit Summary

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Test Your Knowledge

Test Your Knowledge 1.

Float time that can be modeled in the scheduling of the routing include: Choose the correct answer(s).

□ □ □ □ □ 2.

A B C D E

Float before production Float after production Setup time Queue time Teardown time

The duration of an operation consists of a maximum of 5 components. □ □

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True False

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3.

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Determine whether this statement is true or false.

Teardown and wait time are always scheduled simultaneously. Determine whether this statement is true or false.

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Only the minimum wait time is scheduled.

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4.

True False

Determine whether this statement is true or false.

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5.

True False

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Move time is defined only in the operation details. Determine whether this statement is true or false.

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True False

You can only split an operation processing time on a work center with more than 1 individual capacity. Determine whether this statement is true or false.

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Test Your Knowledge

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Operation can be set to overlap so that the next operation starts before the previous operation has finished. Determine whether this statement is true or false.

□ □ 8.

True False

Reduction measures are applied when the lead time schedule of a routing does not fit within the basic date schedule. Determine whether this statement is true or false.

9.

True False

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□ □

Which of the following are types of PRT's? Choose the correct answer(s).

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A B C D E

Material Equipment Component Miscellaneous Document

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□ □ □ □ □

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10. PRT is another name for a component that is used in production. Determine whether this statement is true or false.

11. The same PRT can be assigned to more than one operation on the same routing. Determine whether this statement is true or false.

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True False

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Test Your Knowledge

Answers 1.

Float time that can be modeled in the scheduling of the routing include: Answer: A, B, D Float time that can be modeled in the scheduling of the routing include the float before and after production and queue time sometimes referred to as operation float time.

2.

The duration of an operation consists of a maximum of 5 components.

C S C

Teardown and wait time are always scheduled simultaneously.

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3.

The duration of an operation consists of a maximum of 5 components which are queue time, setup time, processing time, teardown time, and wait time.

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Answer: True

Answer: False

4.

Only the minimum wait time is scheduled.

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Teardown and wait time are scheduled consecutively unless the teardown/wait simul. indicator is set in the operation details of the routing.

Move time is defined only in the operation details.

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5.

Only the minimum wait time is scheduled, the maximum wait time is used for information purposes only.

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Answer: True

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Move time can be defined in the operation details or by location groups in the work center. 6.

You can only split an operation processing time on a work center with more than 1 individual capacity. Answer: True An operation is split if it is carried out on several machines or by several persons at the same time.

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Answer: False

Test Your Knowledge

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Operation can be set to overlap so that the next operation starts before the previous operation has finished. Answer: True To reduce lead time of a routing or production order you can overlap operations. This means that an operation starts before the previous operation has finished.

8.

Reduction measures are applied when the lead time schedule of a routing does not fit within the basic date schedule. Answer: True

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Which of the following are types of PRT's? Answer: A, B, D, E

b y

The 4 types of PRT's are material, equipment, document, and miscellaneous.

Answer: False

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Answer: True

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Unlike components, PRT's are not consumed in the production process and the same PRT can be assigned to multiple operations on the same routing.

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11. The same PRT can be assigned to more than one operation on the same routing.

b y

PRT's like components are needed for production but they are not consumed like components which makes them much different than components.

u s e

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10. PRT is another name for a component that is used in production.

i n t e r n a l

9.

F o r

Reduction measures are applied when the lead time schedule of a routing does not fit within the basic date schedule

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Unit 9 Engineering Workbench Unit Overview

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• • • • • •

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Unit Objectives

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Unit Contents

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Lesson: Structure of the Engineering Workbench ..........................494 Lesson: Navigating in the Engineering Workbench .......................500 Exercise 29: Navigating in the EWB .....................................505 Exercise 30: Navigating in the EWB II...................................509 Lesson: Engineering Workbench Work Areas ..............................516 Exercise 31: Create a Work Area ........................................525

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Use the engineering workbench for routing maintenance Use the EWB browser functions Navigate in the engineering workbench Create a work area Explain the effect of the work area focus Explain the effect of objects contained in the work area

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After completing this unit, you will be able to:

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F o r

This unit introduces the engineering workbench transaction to create and maintain various production planning and execution master data. This transaction can replace the create and change functions for the bill of material and routing. This transaction is typically used to develop and manage complex bills of material and routings.

Unit 9: Engineering Workbench

PLM114

Lesson: Structure of the Engineering Workbench Lesson Overview In this lesson you will learn the benefits of using the engineering workbench. You will learn to navigate in the tool, create your own work area, and copy multi-level.

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

Use the engineering workbench for routing maintenance Use the EWB browser functions

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Introduction to the Engineering Workbench

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The engineering workbench (EWB) is part of the PP module in SAP R/3, and is a complex tool for the integrated processing of BOMs and routings. This means that both object types and their links are maintained simultaneously and in detail, with the same user interface.

i n t e r n a l

You would like to find the optimum maintenance environment for permanent changes to allow multiple users to make changes simultaneously. You would also like to create new master data and link it in a hierarchy.

F o r

Business Example

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Figure 169: Benefits of the Engineering Workbench

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Lesson: Structure of the Engineering Workbench

The concept of the engineering workbench however, goes far beyond the conventional maintenance of BOMs and routings in that all transactions for the conventional maintenance of these objects are brought together and an extensive change management is offered. Using complex selection criteria, any number of objects can be combined; the resulting data then contains no additional information, helping you to achieve a quick overview. The integration of an object browser, as well as various viewers and the digital mock-up viewer, makes the workbench a central object within PLM.

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Often times changes to master data happen in complex processes and groups. These activities can arise from new development, design changes, or changes in procedure. Design changes can be changes that are required due to new products, rules, warranty dates, and so on. Technical changes can occur in BOMs, routings, or new steps in the process (work center). These types of changes call for simultaneous changes to the assembly in the BOMs and to the sequence in the routings.

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Figure 170: Formatting of Specific Information

Unit 9: Engineering Workbench

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The engineering workbench is a maintenance environment for product structures and PP objects. Its capabilities far exceed those of the conventional maintenance of BOMs and routings because you do not have to process routings and BOMs separately.

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The most important objects of the engineering workbench are BOM items and operations. Views are applied to these objects, which then further enable the conventional BOM or routing structures to be used. The full scope of the processing functions, Create, Change, and Delete, is supported in all these views. The worklist contains the selected objects so that they can be displayed, changed, or newly created in the engineering workbench. These objects are copied by the system from the database into the worklist. Only when the worklist has been saved, following the processing of objects, are new objects created in the database or existing ones changed or deleted.

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Figure 171: Worklist: Purpose

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Lesson: Structure of the Engineering Workbench

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Figure 172: Simultaneously Processing Objects in EWB

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The task list header of a routing The operation and sub-operation The production resource/tool, trigger point, and inspection characteristic The BOM header The item and sub-item in the BOM

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• • • • •

b y

To display or process an individual object using the EWB, you have to select the corresponding object. Examples of objects are:

u s e

Structure of the Engineering Workbench

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Different users can work on the same BOM and /or routing simultaneously without locking each other out. Any number of operations from any number of routings can be processed at the same time by different people. The same applies to different BOM items or different operations. If you want to process an object that is already being processed by someone else, the engineering workbench information will show you who to contact, so that you can consult with the other processor. The processor can then release the object to you, without interrupting your work on other objects.

Unit 9: Engineering Workbench

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

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Figure 173: Structure of the Engineering Workbench

C S C

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Lesson: Structure of the Engineering Workbench

Lesson Summary You should now be able to: • Use the engineering workbench for routing maintenance • Use the EWB browser functions

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Unit 9: Engineering Workbench

PLM114

Lesson: Navigating in the Engineering Workbench Lesson Overview In this lesson you will learn the benefits of using the engineering workbench. You will learn to navigate in the tool, create your own work area, and copy multilevel.

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

Navigate in the engineering workbench

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Work areas are created in Customizing for the engineering workbench. Using the Display work area button, you can specify a standard work area or select another work area. In the Select work area dialog box, you also have the option of branching to the detail screen in the working area. In this detail screen, you can read the information about the predefined focus and about the object types contained in the working area.

i n t e r n a l

Data Selection in EWB

F o r

You would like to find the optimum maintenance environment for permanent changes. You would like to make changes simultaneously. You would also like to create new master data and link it in a hierarchy.

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Business Example

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Figure 174: Choosing the Work Area

500

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Lesson: Navigating in the Engineering Workbench

The system automatically offers the tab page in which the object of the focus has been placed. When entering the selection criteria, you can switch the tab page.

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You can also 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. By using the arrow key on the tab page, you can enter into fields additional selection criteria that is not contained as selection criteria in 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 intervals, or generically.

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Figure 175: Selection Criteria

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Figure 176: Effectivity Window

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With the help of the effectivity window, the display of objects is filtered into the overview screen. In this figure above, the example is of a working area with four operations. The operations have been partially changed. If you choose the selection period in the effectivity window, all operations that are effective in the selection period are displayed. If you restrict the effectivity window, the operations that lie completely outside of the effectivity window are not displayed. If you choose the key date in the effectivity window, only those operations that are effective on the key date are displayed.

Navigation in the Engineering Workbench The screen layout is divided into three elements:

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Toolbar Cockpit Overview screen

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The toolbar provides the user with currently available functions at the touch of a button. The cockpit is always available and controls the engineering workbench. It consists of three areas: •

• •

502

Process using, for the entry of the key dates or of the change number, to process 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. Effectivity window, to display a particular time segment of the worklist. Context, to display the hierarchical relationship of objects in the overview screen.

© 2006 SAP AG. All rights reserved.

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Figure 177: Navigation in the EWB

PLM114

Lesson: Navigating in the Engineering Workbench

In this figure below there is an input line for each material, BOM, and item. The overview screen lists objects that are contained in the worklist and that match the entries in the effectivity window and in the context. It provides information about the object and change status of a particular object type.

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If you double-click on an object, the context block is filled in the EWB window and the tab page belonging to it is displayed. The right mouse button provides the functions from the graphics displayed above in a context menu.

u s e

•

In the browser:

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•

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Figure 178: Functional Overview of the EWB

C S C

The copy range has to include the object to be copied. The copy range is predefined with the settings from the working area and also those from the restrictions. No objects an be expanded unless they are contained in the working area. Should the situation arise, check under Extras→ Options→ Copy range.

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Multilevel copy prerequisites:

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Unit 9: Engineering Workbench

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PLM114

Lesson: Navigating in the Engineering Workbench

Exercise 29: Navigating in the EWB Exercise Objectives After completing this exercise, you will be able to: • Navigate in the engineering workbench • Select objects for your work list • Assign materials to routings using the EWB • Change BOMs and routing using EWB • Use EWB locking logic

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1.

Using the P_ALLES working area, select all routings that you created.

2.

How many routings did you create?

3.

Check whether the groups displayed belong to your products.

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Task 1:

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Select the routings that you created.

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b y

Task 2: 1.

When creating the routing for your pump T-F##, it occurs to you that your routing can also be used for the production of pump P-100. Assign material P-100 to your routing.

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2.

In the BOM for pump P-100, change the quantity of the component 100-130 to the number of your group. Who currently has the data locked?

3.

Can you change another BOM item in the same BOM without the lock being lifted?

o n l y

F o r

Using the EWB, create a material-routing assignment.

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F o r

You are responsible for maintaining master data for BOMs and routings in your company. To do this you want to use the common maintenance interface in the engineering workbench.

b y

Business Example

4.

Save the changes and exit the EWB.

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Solution 29: Navigating in the EWB Task 1: Select the routings that you created.

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b y

Choose Logistics → Production → Master Data → Engineering Workbench or use transaction code CEWB.

b)

Select the P_ALLES working area and choose Continue.

c)

Select the Additional Selection Criteria icon .

d)

On the Header tab page, choose More Selection Criteria under the task list section.

e)

In the Explorer window that appears, expand the Task list - Header folder by clicking the triangle to the left of it.

f)

Select Created by and choose Adopt Field Selection .

g)

Complete the field with your user ID and chosoe Save.

h)

Choose Load Task Lists and BOMs .

i)

In the Headers Overview you now see a list of task lists that you created.

How many routings did you create? a)

Four routings and one reference operation set.

Check whether the groups displayed belong to your products. From the menu, choose Task Lists → Material-Task list assignments.

b)

The Material - Routing Assignments Overview screen now shows which materials are assigned to your routings.

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a)

b y

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3.

u s e

u s e

a)

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2.

Using the P_ALLES working area, select all routings that you created.

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Lesson: Navigating in the Engineering Workbench

Task 2: Using the EWB, create a material-routing assignment.

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b y

u s e

Select the routing for T-F## from the list by clicking the button to the left of it in the table.

b)

Choose Copy .

c)

In the dialog box that appears, enter material P-100, plant 1000 in the context section and choose Copy.

d)

When you refresh the screen, the new assignment will appear on the list.

In the BOM for pump P-100, change the quantity of the component 100-130 to the number of your group. Who currently has the data locked? a)

Select the routing-material assignment for P-100 on the Material-routing assignments Overview screen and choose Bills of Material → Items from the menu.

b)

Select the line with 100-130 and choose Change.

c)

A dialog box appears with the information of which group has the data locked.

Can you change another BOM item in the same BOM without the lock being lifted? Save the changes and exit the EWB.

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i n t e r n a l

4.

Yes

b y

a)

u s e

3.

a)

i n t e r n a l

2.

When creating the routing for your pump T-F##, it occurs to you that your routing can also be used for the production of pump P-100. Assign material P-100 to your routing.

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1.

a)

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PLM114

Lesson: Navigating in the Engineering Workbench

Exercise 30: Navigating in the EWB II Exercise Objectives After completing this exercise, you will be able to: • Reassign component assignments • Use the browser to copy and an operation • Create a routing and a BOM by using multi-level copy

Business Example

o n l y

Task 1:

b y

2.

In the operation overview, check the copied operation. Select Save to exit editing in the EWB.

u s e

C S C

Copy operation 50 with its corresponding components from the routing for material R-F1## to operation 45 in the T-F## routing.

Task 2:

i n t e r n a l

First create the material master record for your new pump T-H## by using T-F## as the template and create your default views. Change the description to Rotary Pump W/2 flywheels GR##.

2.

Now create the rest of the master data using the Engineering Workbench.

F o r

Before copying, set the indicator for Set target context after copying on the Misc. tab page.

Task 3: Display the PRT assignments in the Engineering Workbench. 1.

Use the browser to display an overview of the production resources/tools for pump T-F1## in plant 1000. Continued on next page

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The routing should be copied multi-level from the pump with material number T-F## and group counter 1.

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1.

b y

Your company is introducing a new pump T-H## which is similar to T-F## with 2 flywheels. You must create the master data needed to manufacture this new pump.

u s e

1.

i n t e r n a l

Copy an operation for a similar pump.

F o r

You are responsible for maintaining master data for BOMs and routings in your company; to do this you use the common maintenance interface in the Engineering Workbench.

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2.

Search for the production resource/tool INSP-## in your routings by using the browser. Navigate to the details screen.

3.

You have assigned the hollow shaft to operation 40 in your routing for material T-F##. Reassign this assignment to operation 45 by using the browser.

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Lesson: Navigating in the Engineering Workbench

Solution 30: Navigating in the EWB II Task 1: Copy an operation for a similar pump.

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b y

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c)

Select the Additional Selection Criteria icon .

d)

Click Multiple Selection Icon to the right of material and enter R-F1## and T-F## as material numbers.

e)

Click the Load Task Lists and BOMs Icon .

f)

Confirm the dialog box EWB: Process Using with the specified key date.

g)

Click the Activate Browser Icon to activate the browser, enter application PP01.

h)

Expand the routing for R-F1## to the operations by clicking the triangle to the left of R-F1##. Use the same method to navigate to the operations for material T-F##.

i)

Select operation 40 for material R-F1##, right-click and choose Multi-level Copy from the context menu.

j)

Select the standard sequence of the routing for T-F## as the target object. Right-click, choose Paste, and enter operation 45.

k)

The operation and component assignment now appear in the T-F## routing.

In the operation overview, check the copied operation. Select Save to exit editing in the EWB. a)

Right-click the standard sequence in the routing for material T-F## and select Operations to go to the operations overview.

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F o r

Select the P_ALLES working area and click continue.

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b)

b y

Use the menu path Logistics → Production → Master Data → Engineering Workbench or transaction code CEWB.

u s e

a)

i n t e r n a l

2.

Copy operation 50 with its corresponding components from the routing for material R-F1## to operation 45 in the T-F## routing.

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Task 2: Your company is introducing a new pump T-H## which is similar to T-F## with 2 flywheels. You must create the master data needed to manufacture this new pump.

a)

Choose Logistics → Production → Master data → Material master → Material → Create (General) → Immediately (MM01).

b)

Enter the material number T-H## and material type for Finished goods. Enter T-F## as the copy from material.

c)

In the Basic Data 1 view, change the description to Rotary Pump W/2 flywheels GR##.

d)

Choose Save .

Now create the rest of the master data using the Engineering Workbench.

b y

i n t e r n a l

u s e

u s e

b y

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The routing should be copied multi-level from the pump with material number T-F## and group counter 1.

i n t e r n a l

2.

First create the material master record for your new pump T-H## by using T-F## as the template and create your default views. Change the description to Rotary Pump W/2 flywheels GR##.

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Lesson: Navigating in the Engineering Workbench

Before copying, set the indicator for Set target context after copying on the Misc. tab page. a)

Use the menu path Logistics → Production → Master Data → Engineering Workbench or transaction code CEWB.

b)

Select the P_ALLES working area and click continue.

c)

Select the Basic Selection Criteria icon .

d)

Enter T-F## as the material number and 1000 as the Plant number.

e)

Click the Load Task Lists and BOMs Icon

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b y

i)

Select the Multi-level Copy indicator.

j)

button to set the indicators Click the Copy Range Icon for the relevant copy objects (select all) in the EWB: Options dialog box.

k)

If you didn't set it in step b) then in the EWB: Options dialog box, set the Set target context after copying indicator on the Misc. tab page.

l)

Now copy the routing by clicking the copy button.

m)

Change the lot-size validity in the table to 1-100,000 and scroll to the right to be sure planner 0## is assigned.

n)

Save your data.

o)

Be sure to check the Component Assignments, the BOM Header, and BOM Items.

F o r

i n t e r n a l

u s e

In the Target Data dialog box, enter material number T-H##, plant 1000, task list type N Routing and delete the routing group number.

Continued on next page

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h)

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Select the T-F## routing you wish to copy and click the Copy Object Icon .

b y

g)

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First select the Options Icon , choose the Misc. tab and in the Navigate while copying section select Set target context after copying and click Execute.

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Task 3: Display the PRT assignments in the Engineering Workbench. 1.

Use the browser to display an overview of the production resources/tools for pump T-F1## in plant 1000. a)

Use the menu path Logistics → Production → Master Data → Engineering Workbench or transaction code CEWB.

b)

Select the P_ALLES working area and click continue.

c)

Enter T-F1## as material number.

d)

Click the Load Task Lists and BOMs Icon .

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b y

u s e

Select Find

b)

In the Find dialog box, select the object type PRT and enter INSP-##.

c)

Double-click the search result to select the production resource/tool in the upper browser screen. Double-click again in the upper screen to get to the production resource/tools details.

You have assigned the hollow shaft to operation 40 in your routing for material T-F##. Reassign this assignment to operation 45 by using the browser. Drill down in the browser structure and reassign the hollow shaft to operation 45 by clicking and dragging.

b)

Close the browser and exit the EWB without saving.

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a)

b y

i n t e r n a l

.

a)

u s e

3.

Search for the production resource/tool INSP-## in your routings by using the browser. Navigate to the details screen.

i n t e r n a l

2.

Right-click the line in the browser for the reference operation set for material T-F1## and choose Production Resources and Tools.

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Lesson: Navigating in the Engineering Workbench

Lesson Summary You should now be able to: • Navigate in the engineering workbench

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Lesson: Engineering Workbench Work Areas Lesson Overview In this lesson we will investigate the work area and how it affects work in the engineering workbench.

Lesson Objectives After completing this lesson, you will be able to: Create a work area Explain the effect of the work area focus Explain the effect of objects contained in the work area

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• • •

Business Example

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Work Areas

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Work areas are created in Customizing for the engineering workbench. Using the Display work area button, you can specify a standard work area or select another work area.

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Users will need specific work areas to allow them to do their jobs efficiently. You need to understand how to configure work areas to make them efficient for users in your company.

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Figure 179: Work Area Selection

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Lesson: Engineering Workbench Work Areas

In the Select work area dialog box, you also have the option of branching to the detail screen in the working area. In this detail screen you can read the information about the predefined focus and about the object types contained in the working area.

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If the focus is set on the operation, then only those operations that use this work center are read into the worklist. If the focus is set on the routing header, then the operations that are contained in the routings are also read into the worklist.

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•

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An example would be loading operations in the worklist by selecting according to the work center:

b y

A focus object is an object of the focus object type that meets the selection criteria that you enter. An environment object is an object whose object type is contained in the working environment and that is assigned to a focus object. Environment objects are automatically selected by the system and represent the environment of the focus object that you are interested in. Using the selection criteria that you enter, you immediately determine which focus objects are contained in your worklist. The focus objects form the core of your worklist.

u s e

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Figure 180: Objects in the Worklist

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4.

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3.

All BOM headers, with their items and subitems, are copied into the worklist that contains these components. All task list headers belonging to the BOM headers of these components are copied in to the worklist. Additionally, the objects that are connected to the task list header and whose object type is included in the working environment are also copied into the worklist. All component assignments between the items in the BOM headers, and the operations for the corresponding routings, are copied into the worklist.

b y

i n t e r n a l

1.

u s e

The focus lies on the object type BOM header. In addition to the focus on the BOM header, the object types item and subitem, routing header with sequence, operation, PRT, trigger point, and inspection characteristic should all be contained in the working environment. A component has been entered as selection criteria.

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Figure 181: Example: Focus BOM Header

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Lesson: Engineering Workbench Work Areas

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4.

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3.

Only the items that correspond to these components, are copied into the worklist with their BOM headers and subitems. All operations to which this component has been assigned are copied in to the worklist. Additionally, the objects that are connected to this operation and whose object type is contained in the working environment are copied into the worklist, for example, task list header, sequence, and so on. As a further restriction, the material / routing assignment is taken into account.

b y

i n t e r n a l

1.

u s e

The focus lies on the object type item. With the focus on the item, the following object types should also be included in the working environment: BOM header and subitem, routing header with sequence, operation, PRT, trigger point, and inspection characteristic. A component has been entered as selection criteria.

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Figure 182: Example: Focus BOM Item

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Figure 183: Different Focus: BOM

Working area Selection criteria

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b y

• •

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These examples illustrate the expected results of a different focus. The prerequisite for these results is that the working area always contains the same object types. The working area (with focus) and the selection criteria can be viewed in the menu entry Extras:

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Figure 184: Different Work Areas: BOM

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Lesson: Engineering Workbench Work Areas

These examples illustrate the expected results of a different working area. The prerequisite for these results is that the focus is always on the same focus object. The working area (with focus) and the selection criteria can be viewed in the menu entry Extras: • •

Working area Selection criteria

As an example, the focus is defined in reference to the BOM header.

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Figure 185: Example: Focus Task List Header

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The focus lies on the object type routing header. In addition to the focus routing header, the object types sequence, operation, PRT, trigger point, inspection characteristic, BOM header, item, and subitem should all be contained in the working environment. A work center has been entered as selection criteria. 1.

2.

4.

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3.

All routing headers are copied with their sequences and operations into the worklist, provided that one of the operations contains this work center. Additionally, the objects that are connected to the operation, and whose object type is included in the working environment, are also copied into the worklist. All BOM headers that are assigned to these routing headers are copied into the worklist. All objects that are on a lower level to these BOM headers are copied into the worklist. All component assignments that are between the operations of the routing header and the items of the assigned BOM headers are copied into the worklist.

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Figure 186: Example: Focus Operation

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Lesson: Engineering Workbench Work Areas

The focus lies on the operation object type. In addition to the focus operation, the following object types should all be contained in the working environment: routing header, sequence, PRT, trigger point, inspection characteristic, BOM header, item, and subitem. A work center has been entered as selection criteria. 1. 2. 3. 4.

All objects that are at a higher or lower level than the focus objects covered by these work center operations are copied into the worklist. All items that are assigned to these operations, including the component assignments, are copied into the worklist. All objects that are on a higher or lower level than these items are copied into the worklist. The assignments between routing headers and BOM headers, determined in steps 1 and 3, are copied into the worklist.

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The figure above illustrates the expected results of the different focus. Prerequisite for the respective result is that the working area always contains the same object types. The working area (with focus) and the selection criteria can be viewed by choosing Extras → Working Area Details → Selection Criteria Details.

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Figure 187: Routing: Different Focus

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b y

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b y

The figure above illustrates the expected results of a different working area. A prerequisite for the respective results is that both examples use the same focus. The working area (with focus) and the selection criteria can be viewed by choosing Extras → Working area details → Selection criteria details.

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Figure 188: Routing: Different Work Area

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Lesson: Engineering Workbench Work Areas

Exercise 31: Create a Work Area Exercise Objectives After completing this exercise, you will be able to: • Create a work area for use in the engineering workbench

Business Example You need to create different work areas for different users in the engineering workbench.

o n l y

2.

Use your new work area to make a change to the quantity of component 30 of the BOM of T-F##. What is missing in the work area that prevents you from making this change?

b y

Create a work area called PLM## with focus on the BOM header.

u s e

1.

Change your work area, PLM##, to focus on the task list header. Include task list header, operations, and material-routing assignments in the work area.

b y

2.

Use your new work area to assign material components of the BOM of T-F## to operations. What is missing in the work area to be able to make this change?

C S C

u s e

Change your work area to focus on the task list header and include task list header, operations, and material-routing assignments in the work area. Use you work area to assign BOM components to an operation on the routing.

i n t e r n a l

Task 2:

i n t e r n a l

1.

F o r

Create a work area with focus on the BOM header and use it to make a change in a BOM.

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Task 1:

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Solution 31: Create a Work Area Task 1: Create a work area with focus on the BOM header and use it to make a change in a BOM.

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a)

In the IMG, choose Production → Basic Data → Engineering Workbench → Edit Working Areas or use transaction code OP77.

b)

Choose the New entries button.

c)

Enter PLM## as the name of your working area with description Work Area ##.

d)

In the Focus section, select BOM Header.

e)

In the Contained in Work Area section select BOM Header and choose Save.

b y

b)

Select your new PLM## working area and choose Continue.

c)

Enter T-F## as the material number.

d)

Choose the Load BOMs icon.

e)

Try to drill down to the item level in the BOM. The browser doesn't let you, and the menu path Bills of Material → Items is greyed out.

f)

It is not possible to drill down to the item level because only headers were included in the work area.

b y

C S C

i n t e r n a l

From the main menu, choose Logistics → Production → Master Data → Engineering Workbench or use transaction code CEWB.

u s e

a)

u s e

Use your new work area to make a change to the quantity of component 30 of the BOM of T-F##. What is missing in the work area that prevents you from making this change?

i n t e r n a l

2.

Create a work area called PLM## with focus on the BOM header.

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1.

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Continued on next page

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Lesson: Engineering Workbench Work Areas

Task 2: Change your work area to focus on the task list header and include task list header, operations, and material-routing assignments in the work area. Use you work area to assign BOM components to an operation on the routing.

In the IMG, choose Production → Basic Data → Engineering Workbench → Edit Working Areas or use transaction code OP77.

b)

Select your work area, PLM##, and choose Details

c)

In the Focus section, select Header.

d)

In the Contained in Work Area section, select Operations and everything above it in the list will be automatically selected.

e)

Choose Save.

b)

Select your new PLM## working area and choose Continue.

c)

Enter T-F## as the material number.

d)

Choose Load Task Lists and BOMs

e)

Select a routing and choose Task Lists→ Component Assignments. Unfortunately, it is greyed out.

f)

It is not possible to drill down to the item level because BOM items were not included in the work area.

.

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From the main menu, choose Logistics → Production → Master Data → Engineering Workbench or use transaction code CEWB.

b y

a)

u s e

u s e

i n t e r n a l

.

Use your new work area to assign material components of the BOM of T-F## to operations. What is missing in the work area to be able to make this change?

b y

C S C

a)

i n t e r n a l

2.

Change your work area, PLM##, to focus on the task list header. Include task list header, operations, and material-routing assignments in the work area.

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Lesson Summary You should now be able to: • Create a work area • Explain the effect of the work area focus • Explain the effect of objects contained in the work area

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Unit Summary

Unit Summary You should now be able to: • Use the engineering workbench for routing maintenance • Use the EWB browser functions • Navigate in the engineering workbench • Create a work area • Explain the effect of the work area focus • Explain the effect of objects contained in the work area

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Course Summary

PLM114

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

Maintain material masters and bills of materials Maintain routings and work centers Assign material components to operations Managed updates to various master data objects Execute reports on various master data objects Model various manufacturing options in the bill of material and routing Maintain master data using the engineering work bench

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© 2006 SAP AG. All rights reserved.

2006/Q2

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Distribution channel, 12 Division, 12

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field selection, 108 Float before/after production, 450

G Group BOMs, 149

I Individual Capacities, 454 industry sector, 50 see also influencing factors

item category configuration, 195 variable size, 193

L low-level code, 141

M material assignment, 296 Material master, 13 material number, configuring, 50 material status, 89, 106 material type, 48, 105 Move time, 452 MRP area, 32 MRP groups, 57 MRP profile, 56

© 2006 SAP AG. All rights reserved.

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change material archive, 94 delete, 92 extending, 88 mass maintenance, 91 material status, 89 material type, 89 characteristic, 74 class, 74 class type, 74 classification, 72 Client, 8 Company code, 9 component allocation, 298 Continuous flow, 454

engineering change management, 315 engineering change management (ECM), 156

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batch management, 76 batch master record, 76 bill of material, 14 BOM alternative determination, 193 archiving, 160 by-product, 347 co-product, 345 comparison, 180 default settings, 190 explosion report, 178 modification parameters, 189 recursiveness, 154 status, 192 where-used list, 179–180 BOM categories, 135 BOM status, 137 BOM usage, 136 BOM validity, 147

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Index

Index

PLM114

S

Overlapping, 454

Q

Sales Area, 12 Sales organization, 11 Scheduling margin Key, 450 screen sequence, 111 Setup time, 452 Shipping Point, 12 Splitting, 454 storage location, 27 Storage location, 9 subitems, 139 suboperation, 307

Queue time, 451

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R

Tear down time, 452

Reduction measures, 455 routing component allocation, 298 material assignment, 296 reporting, 318 suboperation, 307 user- defined fields, 309 variable-size items, 299 routings, 16

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W Wait time, 452 work center, 15

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unit of measure, 52 groups, 54

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plant definition, 23 Plant, 9 Processing time, 452 PRTs, 480 Purchasing group, 10 Purchasing organization, 10

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532

© 2006 SAP AG. All rights reserved.

2006/Q2

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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