PLM115
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Basic Data for Process Manufacturing
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Participant Handbook Course Version: 2005 Q2 Course Duration: 5 Day(s) Material Number: 50072154
An SAP course - use it to learn, reference it for work
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Copyright Copyright © 2005 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.
American English is the standard used in this handbook. The following typographic conventions are also used.
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Words or characters that appear on the screen. These include field names, screen titles, pushbuttons as well as menu names, paths, and options.
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About This Handbook
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Icons in Body Text The following icons are used in this handbook. Icon
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Contents Course Overview ............................................................................. vii
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Unit 5: Resources ...........................................................................141 Resources: Overview ..................................................................... 142 Capacities .................................................................................. 153 Formulas .................................................................................... 157 Creating Resources and Further Maintenance Activities............................. 162
Unit 6: Production Version ................................................................205 Production Version - Overview........................................................... 206 Maintaining Production Versions ........................................................ 209
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Batches and Batch Management ........................................................ 102 Batch-Specific Material Units of Measure .............................................. 118 Batch Levels................................................................................ 133
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Unit 4: Aspects of Batch Management .................................................101
Classification System ...................................................................... 80 Classifying Objects for Process Manufacturing......................................... 85
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Unit 3: Aspects of the Classification System .......................................... 79
Material Master Record .................................................................... 22 Material Type ................................................................................ 28 Creating and Changing Material Master Records ...................................... 42 Field Selection .............................................................................. 53 Customized Material Master Record ..................................................... 62
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Unit 2: Materials .............................................................................. 21
Process Manufacturing: Functions ......................................................... 2 Master Data for Process Manufacturing ................................................... 5
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Unit 1: Introduction ............................................................................1
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Course Goals.................................................................................vii Course Objectives .......................................................................... viii
Contents
PLM115
Unit 7: Master Recipes (I) ..................................................................227 Master Recipes: Overview ............................................................... 228 Creating Header and Operation Data ................................................... 238
Unit 9: Master Recipes (III) ................................................................313 Process Management: Overview........................................................ 314 Maintenance of Process Instructions ................................................... 317 Reporting, Mass Processing and Copying ............................................. 351
Unit 10: Aspects of the Manufacture of Co-Products ...............................363
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Unit 13: Appendix ...........................................................................463 Material Costing............................................................................ 464 Integration of ECC and SCM (APO)..................................................... 467 Basics of Recipe Management .......................................................... 473
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Engineering Change Management - Overview ........................................ 414 Changes with a Change Master Record................................................ 418 Recipe Approval ........................................................................... 429
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Unit 12: Engineering Change Management, Recipe Approval ....................413
Integration with Quality Management ................................................... 390 In-Process Quality Inspection ............................................................ 394
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Unit 11: Aspects of Quality Inspection During Production ........................389
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Manufacture of Co-Products - Overview................................................ 364 Maintaining Material and BOM........................................................... 367
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Materials in the Master Recipe........................................................... 274 Creating BOM and Material List ......................................................... 277 Material Quantity Calculation............................................................. 291 Example Scenario for Material Quantity Calculation .................................. 299
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Unit 8: Master Recipes (II) .................................................................273
Course Overview This course will prepare you to maintain the master data required for process orders in the SAP component ECC. Software components and releases:
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Target Audience This course is intended for the following audiences:
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Members of project teams who are responsible for introducing the basic data for process manufacturing (consultants, organizers) Managers and employees of the relevant departments
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Course Prerequisites
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Required Knowledge •
SCM300 (Manufacturing Overview)
Recommended Knowledge
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SAPPLM (mySAP PLM Overview) SAPPLM (mySAP SCM Overview)
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SAP Enterprise Core Component 5.0
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Course Overview
PLM115
Course Goals This course will prepare you to: Maintaining the master data required for process orders in the SAP component ECC. This includes: – Material masters and batches – Resources – Production versions – Master recipes and material BOMs Introduction to further aspects of master data maintenance for process manufacturing:
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Using engineering change management and approving master recipes Mapping the manufacture of co-products onto the system Planning quality inspection during production
Course Objectives
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SAP Software Component Information The information in this course pertains to the following SAP Software Components and releases: •
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Creating and managing materials, resources, production versions, master recipes, and material BOMs Using engineering change management for recipe approval Mapping the manufacture of co-products onto the system Mapping quality inspection during production onto the system Making important system settings
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After completing this course, you will be able to:
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Unit 1 Internal
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Introduction Unit Overview
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This chapter introduces you to the most important functions for mapping process production and the master data required for this.
Unit Objectives Name the main functions for mapping process manufacturing onto the system Name and explain the master data required for process manufacturing
Unit Contents
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Lesson: Process Manufacturing: Functions ........................................ 2 Lesson: Master Data for Process Manufacturing .................................. 5 Exercise 1: Master Data for Process Manufacturing ....................... 13
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After completing this unit, you will be able to:
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Unit 1: Introduction
PLM115
Lesson: Process Manufacturing: Functions Lesson Overview This lesson provides an overview of the main functions for mapping process manufacturing using SAP.
Lesson Objectives
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Name the main functions for mapping process manufacturing onto the system
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Business Example You will first get an overview of the main functions for mapping process manufacturing onto the system using SAP.
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After completing this lesson, you will be able to:
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Process Manufacturing: Functions
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Figure 1: Process Manufacturing: Functions
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Lesson: Process Manufacturing: Functions
The main areas providing functions for mapping process manufacturing (named PI on the slide) onto the system are: • •
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Production planning and control is, for example, integrated with: •
The APO Core Interface (CIF) allows ECC master data to be transferred to the SCM system.
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ECC quality management . Using a special interface, external laboratory information systems (LIMS) can be linked to ECC QM. Planning levels preceding production (system ECC and/or system SCM) The master data and functions of ECC Materials Management (such as material, inventory management)
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ECC resource management: The PI-specific master data of resources describes all means of production and persons involved in the production process. ECC master recipe management: The PI-specific master data of master recipes describes the manufacture of one ore more materials in one production run without relating to a particular order. Master recipes are the basis for process orders. ECC process order management: Process orders are created on the basis of master recipes. They describe and monitor the actual production process. ECC process management coordinates the data exchange with the process control level. Process management can be used in fully automated, partially automated and manually operated plants.
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Unit 1: Introduction
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Lesson Summary You should now be able to: • Name the main functions for mapping process manufacturing onto the system
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PLM115
Lesson: Master Data for Process Manufacturing
Lesson: Master Data for Process Manufacturing Lesson Overview This lesson provides an overview of the master data required for process manufacturing
Lesson Objectives •
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After completing this lesson, you will be able to: Name and explain the master data required for process manufacturing
Business Example
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Material and batch Resource Production version Master recipe Material BOM
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Find out about the master data required for process manufacturing:
Master Data
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Figure 2: Master Data
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Unit 1: Introduction
PLM115
Master Data for Process Manufacturing (ECC)
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The material is the central master record in Logistics. In general, SAP defines a material as a substance or commodity that is bought or sold on a commercial basis, or is used, consumed or created in production.
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The resource master data describes the means of production in the production process. A production version determines which alternative BOM is used together with which master recipe for process order production. The master data of master recipes describes the manufacture of one or more materials in one production run without relating to a particular order. Material BOMs are used to represent the structure of products that a company manufactures. They are usually created and maintained from within the master recipe (integrated maintenance).
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A batch is a subset of a material with unique specifications. The batches of one material are managed in separate stocks. With regard to the production process, a batch is a quantity of a material produced in a given production run. This quantity, therefore, represents a non-reproducible unit with unique specifications.
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Master data is data in the SAP system that remains unchanged over an extended period of time. It contains information that is used in the same manner for similar objects.
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Figure 3: Master Data for Process Manufacturing (ECC)
PLM115
Lesson: Master Data for Process Manufacturing
Material
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Figure 4: Material
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Batch
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Figure 5: Batch
In the SAP system, batches always depend on the corresponding materials. Batches are created for a material.
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Unit 1: Introduction
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Resource
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Figure 6: Resource
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Lesson: Master Data for Process Manufacturing
Production Version
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Figure 7: Production Version
Master Recipe
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Figure 8: Master Recipe
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Unit 1: Introduction
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A master recipe defines the following data that is required for the production of materials without relating to a particular order: processing steps, resources, material components, data for quality inspection during production, and control information for the process control level. The master recipe is the basis for the creation of process orders. A process order describes an actual production process and contains, for example, production dates and quantities to be produced.
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Material BOM
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A control recipe contains all the information necessary for the execution of a process order by a certain process control system or process operator. Control recipes are generated from the process instructions in a process order and transferred to the corresponding destination in process control. Process instructions are defined in the master recipe on which the process order is based.
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Bill of material (BOM): A complete, fully structured list of the components that make up a product or assembly. The list contains the object number of each component together with the quantity and unit of measure. Material BOMs are used to represent the structure of products that a company manufactures. You create material BOMs with reference to a material master record. The BOM can comprise items of various item categories, such as stock item, non-stock item, document item, text item.
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Figure 9: Material BOM
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Lesson: Master Data for Process Manufacturing
Material BOMs are usually created and maintained from within the master recipe (integrated maintenance). Material BOM data is, for example, important for: • • •
Material requirements planning Material staging during production Product costing
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Process Manufacturing: Data Flow
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During process planning, planned orders are converted into process orders. The basic dates and production quantities are copied from the planned order. The actual production dates are calculated using the basic dates. You can also create process orders manually. A process order provides a detailed description of the actual production of one or more materials in one production run. It is the main control instrument in production, describing and monitoring all planned and actual data relating to production.
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Production requirements trigger the production process. Production requirements are created in material requirements planning in the form of planned orders. Planned orders define the basic dates and planned quantities for production.
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Figure 10: Process Manufacturing: Data Flow
Unit 1: Introduction
PLM115
A master recipe is used as the basis for a process order. It defines, for example, the planned resources and material components. After a process order has been released for production, process management bundles the process instructions maintained in the order into control recipes. The control recipes are either transferred to a process control system using a specific interface or are displayed online in the form of a process instruction sheet (PI sheet) that can be read and maintained by process operators.
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Process management in turn receives process messages from the process control level and forwards them to various destinations. For instance, it is possible to record confirmations for the process order, transfer actual values of the process to functions for process data documentation and evaluation, post material consumptions or production yields as goods movements and transfer quality data to results recording in QM.
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PLM115
Lesson: Master Data for Process Manufacturing
Exercise 1: Master Data for Process Manufacturing Exercise Objectives
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After completing this exercise, you will be able to: • Log on to the system • Navigate in the process manufacturing menu paths
Business Example Your company is a process manufacturing enterprise.
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You belong to the project team that is implementing the basic data for the process manufacturing functions in the SAP ECC component.
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The basic data that you will define covers materials, batches, resources, and production versions with master recipes and material BOMs.
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You will first get an overview of the main functions for mapping process manufacturing onto the system using SAP and the master data required for this.
Task 1:
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Logging on to the systems: Hint: Your instructor provides the information required for logging on.
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Logging on to the PC USER: PASSWORD:
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Logging on to ECC system CLIENT: USER: PASSWORD: LANGUAGE: EN
Continued on next page
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Unit 1: Introduction
PLM115
Task 2: Overview of the functions of process manufacturing 1.
Use the course material to get an overview of the functional areas for mapping process manufacturing. In addition, get an overview of the relevant menu paths in the ECC system.
Overview of the master data for process manufacturing 1.
Use the course material to get an overview of the master data for process manufacturing.
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In addition, get an overview of the relevant menu paths in the ECC system.
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Task 3:
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Lesson: Master Data for Process Manufacturing
Solution 1: Master Data for Process Manufacturing Task 1: Logging on to the systems:
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Hint: Your instructor provides the information required for logging on. Logging on to the PC USER:
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PASSWORD: Logging on to ECC system
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CLIENT: USER: PASSWORD:
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a)
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LANGUAGE: EN No information required.
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Overview of the functions of process manufacturing
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1.
Use the course material to get an overview of the functional areas for mapping process manufacturing. In addition, get an overview of the relevant menu paths in the ECC system. Overview of the functions of process manufacturing
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SAP Menu → Logistics → Production – Process → (...)
Task 3: Overview of the master data for process manufacturing 1.
Use the course material to get an overview of the master data for process manufacturing. Continued on next page
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Task 2:
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Unit 1: Introduction
PLM115
In addition, get an overview of the relevant menu paths in the ECC system. a)
Overview of the master data for process manufacturing SAP Menu → Logistics → Production – Process → Master Data → (...)
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Lesson: Master Data for Process Manufacturing
Lesson Summary You should now be able to: • Name and explain the master data required for process manufacturing
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Unit Summary
PLM115
Unit Summary You should now be able to: • Name the main functions for mapping process manufacturing onto the system • Name and explain the master data required for process manufacturing
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PLM115
Test Your Knowledge
Name the main functional areas for mapping process manufacturing
2.
Name the main functional areas for mapping the required master data.
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Test Your Knowledge
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Test Your Knowledge
PLM115
Answers 1.
Name the main functional areas for mapping process manufacturing Answer:
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Resource management Master recipe management Process order management Process management
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Name the main functional areas for mapping the required master data. Answer:
SAP
SAP
Material Batch Resource Production version Master recipe Material BOM
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Unit 2 Internal
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Materials Unit Overview This chapter introduces you to material master records.
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Unit Objectives After completing this unit, you will be able to: Explain the structure of a material master record. Create and maintain material types Create and maintain material master records Set up field selection for material masters Set up screen sequence control for material masters
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Lesson: Material Master Record ................................................... 22 Lesson: Material Type............................................................... 28 Exercise 2: Material and Material Type....................................... 33 Lesson: Creating and Changing Material Master Records ..................... 42 Exercise 3: Creating and Changing Material Master Records............. 45 Lesson: Field Selection ............................................................. 53 Exercise 4: Field Selection ..................................................... 57 Lesson: Customized Material Master Record.................................... 62 Exercise 5: Customized Material Master Record ........................... 65
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Unit Contents
Unit 2: Materials
PLM115
Lesson: Material Master Record Lesson Overview This lesson introduces you to the definition and the structure of a material master record.
Lesson Objectives
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After completing this lesson, you will be able to: Explain the structure of a material master record.
Find out about the structure of material master records
Material and Material Master Record: Definition
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A material master record contains data of a descriptive nature (such as size, dimension, weight) and data with control functions (such as material type). In addition to this data, which the user can maintain, the material master record also contains data that is automatically updated by the system (such as stock levels). An alphanumeric material number identifies a material master record in the system. This material number is unique at the client level.
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Materials are created as material master records.
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Material master record A data record containing all the basic information required to manage a material. The data is sorted according to various criteria including data of a descriptive nature and data with control functions. It is sorted according to different criteria.
SAP
Material Substance or commodity that is bought or sold on a commercial basis, or is used, consumed, or created in production.
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Business Example
PLM115
Lesson: Material Master Record
Material Master Record: Views
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Figure 11: Material Master Record: Views
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The views shown to the left are the minimum material master views that must be maintained for in-house production. The additional views to the right are typical for process manufacturing.
Master record data is assigned to different organizational levels of the SAP ECC system. When maintaining specific views, you must therefore enter the organizational units (such as plant, storage location, and purchasing organization) for which you want to maintain the data. For each user, you can specify which views of the material master record may be maintained or displayed.
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In accordance with their different usages, the materials of a company are grouped together in material types. For each material type you specify, for example, which views of a material master record can be accessed.
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A view groups all data on a material created by a particular department (such as Purchasing, MRP, Work scheduling) in the master record.
SAP
Each department of a company needs to maintain different information on a material. Therefore, the material master record comprises different views.
Unit 2: Materials
PLM115
Organizational Levels in ECC
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The controlling area is an organizational unit in accounting used for costing. A company code represents an independent accounting unit, for example, a company within a corporate group. Each company code contains one self-contained set of books. Balance sheets and profit and loss statements, required by law, are created at the company code level. Within production planning and control, the plant is the central organizational unit. A plant is a production facility or a facility used to group storage locations. A plant is a unit performing material requirements planning and inventory management. Therefore, it is an important organizational element for materials management.
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The client represents the highest organizational level. A client is a self-contained unit in an SAP system with separate master records and its own set of tables. A client is, for example, a group of companies with several subsidiaries. The company data of an SAP installation is differentiated according to clients and usually also according to lower organizational levels.
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Organization levels in ECC serve as hierarchical representations of the legal and/or organizational structure of an enterprise. They form a framework that supports all business activities and enable you to design your company structure based on your business processes.
SAP
Figure 12: Organizational Levels in ECC
PLM115
Lesson: Material Master Record
Within a plant, material stocks can be managed separately for different storage locations (inventory management). The valuation area represents the organizational level at which material quantities and values can be managed. For order and product costing, a separate valuation area must exist for each plant.
Organizational Levels and Material Master Data
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Internal
Master record data is assigned to different organizational levels of the SAP ECC system. When maintaining specific views, you must therefore enter the organizational units (such as plant, storage location, and purchasing organization) for which you want to maintain the data. Data at client level: This level contains material data that commonly applies to all lower levels of a client. This includes material descriptions, base units of measure, alternative units of measure, weight, volume, and classification data. This data is accessed using the material number.
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Some material data is valid at all organizational levels, while other data is only valid at certain levels. The material master is designed in a way that it reflects the hierarchical structure of the company and it can be maintained centrally without data redundancy. The material master record information is organized in a hierarchical fashion, according to organizational levels.
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SAP
Figure 13: Organizational Levels and Material Master Data
Unit 2: Materials
PLM115
Data at plant level: This level contains material data that applies to a particular plant. To access the plant data, a plant number must be specified along with the material number. To create a bill of material and a master recipe at least one plant level view must exist for the material master. Data at storage location level: This level contains material data that applies to a particular storage location. To access the storage location data, you need to specify the plant number and the storage location number along with the material number.
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Material Master Record: Navigation and Maintenance
The data screens on the main level are displayed in a standard sequence defined in Customizing. However, you can jump from screen to screen and thus interrupt the standard sequence. To reach the additional data screens, choose the Additional Data pushbutton from within the corresponding view.
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To maintain a material, you enter the material number on the initial screen. You then select the organizational levels and views of the main data screens.
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SAP
Figure 14: Material Master Record: Navigation and Maintenance
PLM115
Lesson: Material Master Record
Lesson Summary You should now be able to: • Explain the structure of a material master record.
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Unit 2: Materials
PLM115
Lesson: Material Type Lesson Overview This lesson introduces you to material types.
Lesson Objectives •
Internal
Only
After completing this lesson, you will be able to: Create and maintain material types
Business Example
Material Type •
SAP
–
are used for summarizing materials with the same basic attributes. for example, raw materials, semi-finished products or finished products
Use
Determine certain attributes of the material and have important control functions
To be able to manage different materials in the same way according to the company's requirements, materials with the same attributes are divided into groups and given a material type.
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Within a company, different materials are used for different purposes. Material master records must therefore meet different requirements with regard to views to be maintained and control of certain business transactions.
Partner
–
SAP
•
When creating a material master record, the material must be assigned to a material type. Material types
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You are to create enterprise-specific material types.
PLM115
Lesson: Material Type
Control Using Material Type
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SAP
Figure 15: Control Using Material Type
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Unit 2: Materials
PLM115
The material type controls, for example: • • • • •
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•
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Whether quantity changes are updated in the material master record Whether value changes are also updated in balance sheet accounts in financial accounting
Only
Internal
• •
Partner
In conjunction with the plant the material type determines the inventory management requirement of the material, that is:
SAP
• •
Use
Partner
•
Internal
• • • •
The field selection and screen sequence for material master maintenance The access to material data by means of authorization groups Whether a material number can be assigned internally and/or externally From which number range interval the material number is taken Whether externally assigned material numbers are checked against a number range How the material item category for SD documents is determined Whether material costing is to take place with or without a quantity structure Whether the initial status of a material batch is to be Unrestricted or Restricted Whether the material is intended for a special purpose (for example, as a configurable material or process material) Which procurement type is assigned to the material. This means whether the material is intended for external procurement (external purchase order) and/or in-house production (internal purchase order). Which user department data can be entered, that is, which views are allowed for material maintenance Price control The determination of G/L accounts to be updated in valuation-relevant transactions (for example, goods movement)
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PLM115
Lesson: Material Type
Material Types in the Standard System: Examples
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Figure 16: Material Types in the Standard System: Examples
SAP Use
If required, you can define your own material types. Changing material types:
•
You can change the material type without restrictions if no stocks, reservations, or purchasing documents exist for the material. If stocks, reservations, or purchasing documents exist, you can only change the material type provided that: – –
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The same G/L account is used The same quantities and values are updated
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Internal
•
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The material types most frequently used in production planning and control include FERT, HALB and ROH.
SAP
The graphic shows the main settings for some of the material types available in the standard system (FERT: finished product; HALB: semi-finished product; ROH: raw material; PIPE: pipeline material; PROC: process material; INTR: intra material).
Unit 2: Materials
PLM115
Industry Sector • •
When creating a material master record, the material must be assigned to an industry sector. An industry sector: –
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Internal
–
Specifies the branch of industry to which the material is assigned, for example, chemical industry, pharmaceuticals, food Influences the screen selection and screen sequence for material master maintenance
SAP
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Lesson: Material Type
Exercise 2: Material and Material Type Exercise Objectives After completing this exercise, you will be able to: • Create and maintain material masters • Describe the functions of material types
Only
Internal
Business Example In a first step of master data maintenance, you must: •
Create material master records
•
Define your own material types if required
Use
Partner
and
Task 1: Material Master Record: Navigation and Maintenance
SAP
Go to the following material master in change or display mode:
SAP
1.
Material: T-FJ1## 2.
Select view(s):
Use
Partner
Which views have been maintained for the material? Choose the Basic Data view and some other views. 3.
Organizational levels:
4.
Navigate through the material master views you selected. Then go to views that you have not selected when accessing the material master.
5.
Navigate to the additional data level. Which alternative units of measure have been maintained, for example?
6.
Display the administrative data (information on material). For which industry sector and material type was the material created? Which users have created or changed which views and when? Continued on next page
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Internal
Use the input help (F4) to select a plant and storage location.
Unit 2: Materials
PLM115
Task 2: Settings for material types Display the material types defined in Customizing for finished products, semi-finished products, raw materials, and pipeline materials.
1.
Write down the settings for the parameters in the following table:
Partner
Parameters
Finished product
Semifinished Product
Raw material
Pipeline material
Material type
Use
Are internal orders allowed?
SAP
SAP
Are external orders allowed?
Use
Partner
Which fields are selected in the User departments group box?
Internal
Work scheduling? Accounting?
Only
MRP? Purchasing? Costing?
Continued on next page
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Internal
Only
Caution: Make sure you do not change the data in Customizing. Exit the Customizing view without saving when you have completed the exercise.
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PLM115
Lesson: Material Type
Parameters
Finished product
Semifinished Product
Raw material
Pipeline material
Sales? Which price control is set?
Only Partner
Which function does the field “External no. assignment w/o check have”?
3.
Which function does the “With Qty Structure” field have?
SAP Partner
Internal
Use
SAP
Use
2.
Internal
Does a quantity and value update take place for the material type?
Task 3: Creating a new material type
Only
1.
a) Create a new Material type PI## Material Type Group ## as a copy of (Template) material type HALB semi-finished product. b) Notice the following about the new material type: - External and internal orders are allowed. Continued on next page
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Unit 2: Materials
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- Externally assigned material numbers are checked against a number range. - Material costing with a quantity structure (BOM, task list) is defined.
Work scheduling
Costing
Accounting
Basic data
Classification
Plant stocks
MRP
Storage location stocks
- In all valuation areas, quantities and values are to be updated for materials of this material type. - All materials of this material (not changeable) are to be valuated according to the moving average price.
SAP
Save the material type.
SAP
- Account assignment is to take place according to account class reference 0008, in the same way as for material type HALB.
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Purchasing
Internal
Only
- For materials of this material type, the following user departments may be maintained:
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Internal
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Lesson: Material Type
Solution 2: Material and Material Type Task 1: Material Master Record: Navigation and Maintenance 1.
Go to the following material master in change or display mode: Material: T-FJ1##
Only
2.
(...) → Material Master → Material → Display → Display Current
Internal
a)
Select view(s): Which views have been maintained for the material? a)
3.
The view selection contains the views that have been created for the material so far.
Use
Partner
Choose the Basic Data view and some other views.
Organizational levels: Use the input help (F4) to select a plant and storage location.
SAP
4.
See exercise
Navigate through the material master views you selected. Then go to views that you have not selected when accessing the material master.
Use
You can use the Enter key to navigate through the views selected.
Partner
a)
By choosing the relevant tab page, you can navigate to the views you did not select on the initial screen.
Internal
5.
Navigate to the additional data level. Which alternative units of measure have been maintained, for example?
6.
Choose the Additional Data and then the Units of Measure tab.
Only
a)
Display the administrative data (information on material). For which industry sector and material type was the material created? Which users have created or changed which views and when? a)
Choose the i button (Information on Material).
Continued on next page
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a)
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Unit 2: Materials
PLM115
Task 2: Settings for material types Display the material types defined in Customizing for finished products, semi-finished products, raw materials, and pipeline materials.
Parameters
Finished product
Semifinished Product
Raw material
Pipeline material
Material type
FERT
HALB
ROH
PIPE
Are internal orders allowed?
Yes
Yes
No
No
Are external orders allowed?
Allowed with warning
Yes
Yes
No
Work scheduling?
Yes
Yes
No
No
Accounting?
Yes
Yes
Yes
Yes
MRP?
Yes
Yes
Yes
No
Purchasing?
Yes
Yes
Yes
Yes
Costing?
Yes
Yes
Yes
No
SAP
SAP
Write down the settings for the parameters in the following table:
Use
Partner
1.
Only
Use Internal
Partner
Which fields are selected in the User departments group box?
Continued on next page
38
Internal
Only
Caution: Make sure you do not change the data in Customizing. Exit the Customizing view without saving when you have completed the exercise.
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Lesson: Material Type
Finished product
Semifinished Product
Raw material
Pipeline material
Sales?
Yes
Yes
No
No
Which price control is set?
Standard price
Standard price
Moving average price
Moving average price
Does a quantity and value update take place for the material type?
Depends on valuation area
Depends on valuation area
Depends on valuation area
In none of the valuation areas
2.
SAP Menu → Tools → Customizing → IMG → Execute Project / Pushbutton SAP Reference IMG SAP Customizing Implementation Guide → Logistics - General→ Material Master → Basic Settings → Material Types → Define Attributes of Material Types. Double-click the relevant material type.
SAP
SAP
a)
Use
Partner
Parameters
Which function does the field “External no. assignment w/o check have”?
Use
Which function does the “With Qty Structure” field have?
Only
Internal
Answer: Choose F1 on the field. This field is used to control whether material costing is carried out with or without a quantity structure (BOM and task list).
Task 3: Creating a new material type 1.
a) Create a new Material type PI## Material Type Group ## as a copy of (Template) material type HALB semi-finished product. Continued on next page
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Answer: Choose F1 on the field. If the indicator is set, the material number can be assigned externally without being compared with the number range for the material type. 3.
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Unit 2: Materials
PLM115
b) Notice the following about the new material type: - External and internal orders are allowed. - Externally assigned material numbers are checked against a number range. - Material costing with a quantity structure (BOM, task list) is defined.
Costing
Accounting
Basic data
Classification
Plant stocks
MRP
Storage location stocks
Purchasing - In all valuation areas, quantities and values are to be updated for materials of this material type.
SAP
- Account assignment is to take place according to account class reference 0008, in the same way as for material type HALB.
Use
a)
Creating a new material type
Internal
Customizing (...) → Logistics - General → Material Master → Basic Settings → Material Types → Define Attributes of Material Types b)
Select material type HALB
Only
Copy as... icon Overwrite material type HALB with new material type PI## Make further settings as described.
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Save the material type.
SAP
- All materials of this material (not changeable) are to be valuated according to the moving average price.
Use
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Work scheduling
Internal
Only
- For materials of this material type, the following user departments may be maintained:
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Lesson: Material Type
Lesson Summary You should now be able to: • Create and maintain material types
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SAP
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Unit 2: Materials
PLM115
Lesson: Creating and Changing Material Master Records Lesson Overview This lesson introduces you to the creation and maintenance of material master records.
Lesson Objectives •
Create and maintain material master records
Business Example
Partner
You create the material master records required for the materials in your company.
Use
Creating a Material Master Record
Internal
Only
After completing this lesson, you will be able to:
SAP
SAP Only
Internal
Use
Partner
Figure 17: Creating a Material Master Record
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Lesson: Creating and Changing Material Master Records
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Figure 18: Extending a Material Master Record
SAP
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Figure 19: Functions of Material Master Maintenance
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Unit 2: Materials
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Internal
SAP
SAP Only
Internal
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PLM115
Lesson: Creating and Changing Material Master Records
Exercise 3: Creating and Changing Material Master Records Exercise Objectives
Only
Task 1:
You create material master records that are required for the example scenario of the course.
Internal
Business Example
Partner
After completing this exercise, you will be able to: • Create material master records
Default settings for industry sectors and organizational levels
Use
1.
To make entering data easier, define default data for the industry sector and organizational level before you create your material master records.
SAP
SAP
Choose: Industry sector: Chemical industry You want to hide the industry sector on the initial screen.
Partner
Use
Organizational levels Plant: 1100 Copy from
Internal
Plant: 1100 You want to display the organizational levels only on request.
Only
Task 2: Creating material master records 1.
Raw Material Create the following material of material type ROH Raw material by copying the material given in the table below:
Continued on next page
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Unit 2: Materials
PLM115
Material
Material type
Copy from
T-RD1##
Raw Material
T-RD100
On the Select View(s) screen, select all of the views. Set the Create views selected indicator.
Material
Material description
T-RD1##
Sulfuric acid
Internal
Only
On the Basic Data 1 screen, check the following description for your material:
2.
Finished product
Material
Material type
Copy from
T-FD1##
Finished product
T-FD100
SAP
SAP
Create material T-FD1## of material type FERT Finished product by copying the reference material T-FD100:
Use
Partner
Save your material master record.
On the Select View(s) screen, select all of the views.
Internal
On the Basic Data 1 screen, store the following description for your material: Material
Material description
T-FD1##
Detergent, group ##
Partner
Use
Set the Create views selected indicator.
Save your material master record.
Only
Task 3: Displaying material master records 1.
Display the following materials. What type of materials are they and which material types are assigned to them?
Continued on next page
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Lesson: Creating and Changing Material Master Records
Material
Industry sector
Material type
Material description
T-RD2## T-RD3## T-RD4## T-RD5##
Only
Use
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Internal
These materials will be used for the production of the finished product T-FD1## along with the raw material you created in exercise 1-1.
SAP
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Unit 2: Materials
PLM115
Solution 3: Creating and Changing Material Master Records Task 1: Default settings for industry sectors and organizational levels To make entering data easier, define default data for the industry sector and organizational level before you create your material master records.
Internal
Only
1.
Choose: Industry sector: Chemical industry
Partner
You want to hide the industry sector on the initial screen. Organizational levels Plant: 1100
Use
Copy from Plant: 1100
SAP
SAP Only
Internal
Use
Partner
Continued on next page
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PLM115
Lesson: Creating and Changing Material Master Records
You want to display the organizational levels only on request. a)
Default settings for industry sectors and organizational levels SAP Menu → Logistics → Production - Process → Master Data → Material Master → Material → Create (General) → Immediately Enter material type, such as ROH Raw material. Enter industry section, such as Chemical industry
Only
Internal
Settings → Industry sector. Industry sector: Chemical industry Hide industry sector on initial screen
Partner
Settings → Organizational levels... Plant: 1100
Use
Template Plant: 1100 Organizational levels/profiles on request only
SAP Use
Creating material master records 1.
Raw Material
Material
Material type
Copy from
T-RD1##
Raw Material
T-RD100
Only
Internal
Create the following material of material type ROH Raw material by copying the material given in the table below:
On the Select View(s) screen, select all of the views. Set the Create views selected indicator. On the Basic Data 1 screen, check the following description for your material:
Continued on next page
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Task 2:
SAP
Hint: You can also maintain the user settings in Customizing: (...) Logistics - General → Material Master → Configuring the Material Master → Maintain User Settings.
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Unit 2: Materials
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Material
Material description
T-RD1##
Sulfuric acid
Save your material master record. a)
Raw Material (…) → Material Master → Material → Create - General → Immediately
Only
Select all in the view selection. Create selected views indicator
2.
Finished product
Material
Material type
Copy from
T-FD1##
Finished product
T-FD100
Use
Partner
Create material T-FD1## of material type FERT Finished product by copying the reference material T-FD100:
Internal
b)
Set the Create views selected indicator.
Material
Material description
T-FD1##
Detergent, group ##
Partner
Use
On the Basic Data 1 screen, store the following description for your material:
Finished product (…) → Material Master → Material → Create - General → Immediately
b)
Select all in the view selection. Create selected views indicator
Task 3: Displaying material master records 1.
Display the following materials. Continued on next page
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Internal
Save your material master record. a)
SAP
SAP
On the Select View(s) screen, select all of the views.
PLM115
Lesson: Creating and Changing Material Master Records
What type of materials are they and which material types are assigned to them? Material
Industry sector
Material type
Material description
T-RD2## T-RD3## T-RD4##
Only
These materials will be used for the production of the finished product T-FD1## along with the raw material you created in exercise 1-1.
SAP
Industry sector
Material type
Material description
T-RD2##
C
ROH
Lauryl Alcohol
T-RD3##
C
PIPE
Water
T-RD4##
C
ROH
1-Butanol
T-RD5##
C
ROH
Sodium hydroxide
SAP
Material
Use
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a)
Internal
T-RD5##
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Unit 2: Materials
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Lesson Summary You should now be able to: • Create and maintain material master records
Use
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Internal
SAP
SAP Only
Internal
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Lesson: Field Selection
Lesson: Field Selection Lesson Overview This lesson introduces you to the settings for the field selection for material master records.
Lesson Objectives
Only
•
Internal
After completing this lesson, you will be able to: Set up field selection for material masters
Partner
Business Example For special material types you have to set up the field selection of material master records enterprise-specifically.
Use
Field Selection: Influencing Factors
SAP
SAP Only
Internal
Use
Partner
Figure 20: Field Selection: Influencing Factors
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Unit 2: Materials
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Field Selection: Influencing Factors and Field References
Use
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Internal
Figure 21: Field Selection: Influencing Factors and Field References
SAP
Field Selection: Field Selection Group
SAP
You can set or define field references for the material type, plant, and industry sector.
Use
Each influencing factor is assigned its own field reference for field selection.
The field references for the other influencing factors are predefined.
Only
Internal
Partner
Figure 22: Field Selection: Field Selection Group
Material master fields are grouped in field selection groups.
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Lesson: Field Selection
Field Selection: Field Selection Groups and Field References
SAP
SAP
Use
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Only
Internal
Figure 23: Field Selection: Field Selection Groups and Field References
All field selection groups are assigned to all field references.
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Only
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The field options (hide, display, required entry, optional entry) are defined for each field selection group and field reference.
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Unit 2: Materials
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Field Selection: Link Rules
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Internal
Figure 24: Field Selection: Link Rules
SAP
plant, ...) .
Use
The entries of all field options for the relevant operation are linked to one another for each field selection group.
Internal
The link rules shown in the graphic determine which fields are selected for a field selection group.
Only
In order of priority, the signs mean the following: - Hide * Show + Required entry . Optional entry
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The field references define the field options (hide, show, required entry, optional entry) for the individual field selection groups.
SAP
The field selection is determined by the field references of several influencing factors (material type,
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Lesson: Field Selection
Exercise 4: Field Selection Exercise Objectives After completing this exercise, you will be able to: • Set up field selection for material masters
Only Partner
Field selection settings for the material type
1.
Internal
For special material types you have to set up the field selection of material master records enterprise-specifically.
SAP
Business Example
Task: The following fields are to be Required Entries for materials of material type PI##: (MARA-BISMT)
Material status (cross-plant)
(MARA-MSTAE)
Use
Old material number
SAP
To which field selection groups do these fields belong? MARA-BISMT: ___
Use
2.
Partner
MARA-MSTAE: ___ Which fields belong to these groups? Field selection group 11: _______________
Internal
Field selection group 155: _______________ 3.
Create your own
Only
Field selection reference Z## as a copy of Field selection reference HALB Specify for field selection reference Z## that the above fields are required entry fields. Save your settings. Continued on next page
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Unit 2: Materials
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4.
Assign the field reference Z## to your material type PI##.
5.
Test your settings, for example by creating the basic data views for Material T-PI## of material type PI## Note which views the system displays.
Only
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Note that the above fields now require an entry.
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Internal
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PLM115
Lesson: Field Selection
Solution 4: Field Selection Task: Field selection settings for the material type
Old material number
(MARA-BISMT)
Material status (cross-plant)
(MARA-MSTAE)
1.
Internal
Only
The following fields are to be Required Entries for materials of material type PI##:
To which field selection groups do these fields belong? MARA-MSTAE: ___ a)
Determining the field selection groups: Customizing: Logistics - General → Material Master → Field Selection → Assign Fields to Field Selection Groups
Use
Partner
MARA-BISMT: ___
SAP
SAP
→Goto → Position Cursor ... MARA-BISMT: Field selection group 11 MARA-MSTAE: Field selection group 155
Use
Which fields belong to these groups? Field selection group 11: _______________ Field selection group 155: _______________
Internal
a)
Customizing: Logistics - General → Material Master → Field Selection → Maintain Field Selection for Data Screens
Only
Enter field selection group 11 in the relevant field and choose Enter to confirm. Only the MARA-BISMT field belongs to field selection group 11. Now enter field selection group 155. The MARA-MSTAE field and the MARA-MSTDE field belong to group 155. 3.
Create your own Field selection reference Z## Continued on next page
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as a copy of Field selection reference HALB Specify for field selection reference Z## that the above fields are required entry fields. Save your settings.
Only
Select the line for field reference HALB and choose Edit → Copy As... Overwrite the reference HALB with your target reference Z## and choose Enter to confirm.
Save your settings. 4.
Assign the field reference Z## to your material type PI##. a)
Customizing: Logistics - General → Material Master → Basic Settings → Material Types → Define Attributes of Material Types
SAP
SAP
Select your material type PI## and choose Goto → Details. Field reference: Z## Save your settings.
Use
Test your settings, for example by creating the basic data views for
Partner
5.
Material T-PI## of
Internal
material type PI## Note which views the system displays.
Only
Note that the above fields now require an entry. a)
60
See exercise description
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Partner
Now set the Reqd entry indicator for the field selection groups 11 and 115 for your field reference Z##.
Internal
a)
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Lesson: Field Selection
Lesson Summary You should now be able to: • Set up field selection for material masters
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Internal
SAP
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Internal
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Unit 2: Materials
PLM115
Lesson: Customized Material Master Record Lesson Overview This lesson introduces you to the settings for the screen sequence control for material master records.
Lesson Objectives
Only
•
Set up screen sequence control for material masters
Partner
Business Example For special material types and user groups you have to set up the screen sequence control of material master records enterprise-specifically.
Internal
After completing this lesson, you will be able to:
Use
Customized Material Master
SAP
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Internal
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Figure 25: Customized Material Master
Customized material masters support sufficient data maintenance by creating entry dialogs specific to your company's data requirements.
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Lesson: Customized Material Master Record
The material master is a set of logical screens organized in a specific sequence when more than one view is selected. This organization of logical screens is referred to as a screen sequence. Each logical screen consists of several programmed sets of material master fields. In ECC these are called screen modules or subscreens. The field assignments to a screen module cannot be changed in Customizing. In Customizing for the Material Master you can:
Only
Maintain screen sequences and screens Control the selection of a screen sequence using the influencing factors.
Internal
• •
Use
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Configuring Customized Material Masters
SAP
SAP
Internal
Use
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Figure 26: Configuring Customized Material Masters
Only
Additional notes: When you create your logical screens, we recommend using the standard screen modules that already exist. You need your own screen modules if you require non-standard field groupings or new fields. To create your own screen modules, copy the standard program SAPLMGD1 into your own function group (for instructions, see IMG). Then you can create the subscreens you require in the new function group.
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Append structures are defined in the Data Dictionary so that you can integrate your own fields. You can only integrate fields from user-specific tables and user-specific subsreen containers in the SAPLMGMM program by using modifications. You have to use the Implementation Guide to create your own material master dialogs.
SAP
Only SAP
Use
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Internal
Influencing Factors for Screen Sequences
Figure 27: Influencing Factors for Screen Sequences
Use
The screen references for transactions are predefined.
In the example in the graphic, the screen sequence 01 would be valid for all users who are assigned to the “MU” reference, irrespective of industry sector and material type.
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Internal
The screen sequence becomes valid for the appropriate user, material types, and industry sectors by assigning a combination of screen references to a screen sequence.
Partner
You can create one screen reference per user, material type, and industry sector.
PLM115
Lesson: Customized Material Master Record
Exercise 5: Customized Material Master Record Exercise Objectives
Only
Task:
Internal
Business Example
Partner
After completing this exercise, you will be able to: • Set up screen sequence control for material masters
For special material types and user groups you have to set up the screen sequence control of material master records enterprise-specifically.
Creating a customized material master
Use
1.
Set up a user-specific screen sequence Y# or Z# screen sequence grp.##
SAP
SAP
for material master maintenance. Caution: Agree on the number with the other course participants!
screen sequence 21 Ind-Std short TabStrips 2.
From data screen 08 (Basic data 2) module Environment (2010) is to be copied to data screen 07 (Basic data 1). Then delete data screen 08 and call data screen 07 Basic data.
3.
Set up the following order of screens for your screen sequence Y## or Z##, for example:
Only
Internal
as the template.
1. Screen 1 Basic data 2. Screens Material requirements planning 1 - 4 3. Screen 1 Work scheduling 4. Screens General plant data/storage 1 -2 5. Screen 1 Classification Continued on next page
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The remaining sequence is not to be changed. 4.
The screen sequence is to be valid for your user PI-## (or the user with which your logged on to the system). Define a screen reference for your user (suggestion: call the screen reference with reference to your screen sequence number). Define a new screen sequence control for this screen reference for all material types and sectors of industry. Check your settings by displaying, for example, the material master record T-RD2##.
Use
Partner
Caution: Undo the changes from exercise part 4 with regard the following exercises.
Internal
Only
5.
SAP
SAP Only
Internal
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Lesson: Customized Material Master Record
Solution 5: Customized Material Master Record Task: Creating a customized material master 1.
Set up a
Only
Internal
user-specific screen sequence Y# or Z# screen sequence grp.## for material master maintenance.
Partner
Caution: Agree on the number with the other course participants! Use screen sequence 21 Ind-Std short TabStrips Customizing: Logistics - General → Material Master → Configuring the Material Master → Define Structure of Data Screens for Each Screen Sequence Select the line for the screen sequence 21 and choose Edit → Copy As...
Use
Only
Internal
Save your screen sequence.
Partner
Overwrite the reference sequence HALB with your target reference Y# or Z# and choose Enter to confirm.
SAP
SAP
a)
Use
as the template.
Continued on next page
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2.
From data screen 08 (Basic data 2) module Environment (2010) is to be copied to data screen 07 (Basic data 1). Then delete data screen 08 and call data screen 07 Basic data. a)
Select your screen sequence and double-click Data screens in the dialog structure. Select data screen 08 Basic data 2 and double-click Subscreens in the dialog structure.
Only
Go to the Change View: Data Screens: Overview screen by double-clicking Data Screens in the dialog structure. Select data screen 07 Basic data 1 and double-click Subscreens in the dialog structure.
SAP
Choose View data screen. The screen module Environment is now copied to the data screen Basic data 1. Choose Cancel to exit the simulation.
Use
Save your changes. 3.
Set up the following order of screens for your screen sequence Y## or Z##, for example: 1. Screen 1 Basic data 2. Screens Material requirements planning 1 - 4 3. Screen 1 Work scheduling 4. Screens General plant data/storage 1 -2 5. Screen 1 Classification Continued on next page
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Only
Internal
Change the screen description and the alternative screen description of data screen 07 to Basic Data.
Partner
Double-click Data screens in the dialog structure. Select data screen 08 Basic data 2 and choose Edit → Delete.
SAP
Add the screen module Environment to this data screen by overwriting the screen number 0001 (= empty screen module) with the number 2010.
Use
Partner
Now select the subscreen with the Screen number 2010 and choose View Subscreen. The screen module Environment is displayed. Again, choose Cancel to exit the simulation.
Internal
Choose View data screen. Take a look at the simulation of the logical screen. Choose Cancel to exit the simulation.
PLM115
Lesson: Customized Material Master Record
The remaining sequence is not to be changed. a)
Customizing: Logistics - General → Material Master → Configuring the Material Master → Maintain the Order of Main Screen and Additional Screens Select your screen sequence and choose Goto → Details.
Only
Example : MRP 1 → No.: 11 MRP 3 → No.: 13 and so on Choose Sort Main Screens. The screens are put in a new order. Save your changes.
SAP
The screen sequence is to be valid for your user PI-## (or the user with which your logged on to the system).
SAP
4.
Use
Partner
MRP 2 → No.: 12
Internal
Assign ascending numbers to the screens MRP 1-4, Work Scheduling, and Gen. Plant Data / Storage 1-2 in this order so that their numbers are between the numbers for data screen Basic Data and Classification.
Only
Internal
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Define a screen reference for your user (suggestion: call the screen reference with reference to your screen sequence number). Define a new screen sequence control for this screen reference for all material types and sectors of industry. a)
Customizing: Logistics - General → Material Master → Configuring the Material Master → Assign Screen Sequences to User/Material Type/Transaction/Industry Sector
Enter the user name PI-## (or the user with which you are logged on to the system) in the first column and a two-character screen reference in the second column.
Partner
Suggestion: Call your screen reference similar to your screen sequence number Y## or Z##.
Internal
Only
Double-click User screen reference in the dialog structure and then choose New Entries.
Save your entries.
SAP Use
ScnRef. MatType
ScnRef. Industry sector
Ssq
01
Your screen reference, for example, Y## or Z##
*
*
Y# or Z#
Internal
Save your screen sequence control. 5.
Check your settings by displaying, for example, the material master record T-RD2##.
Partner
ScnRef. User
SAP
ScnRef. Transact
Use
Double-click Screen sequence control in the dialog structure and then choose New Entries. Enter the following:
Only
Continued on next page
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Lesson: Customized Material Master Record
Caution: Undo the changes from exercise part 4 with regard the following exercises. a)
SAP Easy Access menu: Logistics → Production -Process → Master Data → Material Master → Material → Display → Display Current Material: for example, T-RD2##
Internal
Only
Note the sequence of the views in view selection. Choose the Basic Data view. The screen module Environment appears. Undoing the changes from exercise part 4:
Use
Partner
Delete your screen sequence control in Customizing by choosing Edit → Delete.
SAP
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Internal
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Lesson Summary You should now be able to: • Set up screen sequence control for material masters
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Internal
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Unit Summary
Unit Summary You should now be able to: • Explain the structure of a material master record. • Create and maintain material types • Create and maintain material master records • Set up field selection for material masters • Set up screen sequence control for material masters
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Unit Summary
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Internal
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Test Your Knowledge
Partner
2.
Name such functions that are controlled by the material type.
3.
Which information is required for creating a material master record?
4.
Which influencing factors are used to control the field selection for material master records?
5.
Name the influencing factors for the screen sequence control.
© 2005 SAP AG. All rights reserved.
Internal
Only
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Use
SAP
SAP
Name the minimum scope of views that has to be maintained in the material master for in-house production.
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1.
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Test Your Knowledge
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Answers 1.
Name the minimum scope of views that has to be maintained in the material master for in-house production. Answer:
Name such functions that are controlled by the material type.
Use
Only Partner
2.
Basic data MRP Work scheduling Accounting Costing Plant and storage location stock
Internal
• • • • • •
Answer:
SAP Use Internal
Partner
3.
Field selection and screen sequence Number assignment (check external number Y/N) Costing control (with / without quantity structure) Initial state of a batch Internal / external purchase orders (permitted / not permitted) User departments (allowed views for material maintenance) Valuation: price control (standard price / moving average price) Quantity/value update
SAP
• • • • • • • •
Which information is required for creating a material master record?
• • • • • •
76
Only
Answer: Material number (ext./int. number assignment) Material type Industry sector Views to be created Organizational levels Possibly, profiles
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Test Your Knowledge
4.
Which influencing factors are used to control the field selection for material master records? Answer:
Only
5.
Transaction Material type Plant Industry sector Procurement indicator
Internal
• • • • •
Name the influencing factors for the screen sequence control.
• • • •
Transaction User Material type Industry sector
Use
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Answer:
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Unit Summary
PLM115
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Internal
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Unit 3 Internal
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Aspects of the Classification System Unit Overview
Partner
• •
Create and maintain classes and characteristics Name the main class types used for process manufacturing and describe their functions
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Only
Internal
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Lesson: Classification System ..................................................... 80 Lesson: Classifying Objects for Process Manufacturing........................ 85 Exercise 6: Classifying Objects for Process Manufacturing ............... 87
SAP
Unit Contents
After completing this unit, you will be able to:
Use
Unit Objectives
SAP
This chapter introduces fundamental aspects of the classification system.
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Unit 3: Aspects of the Classification System
PLM115
Lesson: Classification System Lesson Overview This lesson introduces you to the task and the fundamental working of the classification system.
Lesson Objectives
Only
•
Internal
After completing this lesson, you will be able to: Create and maintain classes and characteristics
Partner
Business Example Find out about the task and basic functions of the classification system.
•
Use
Purpose of the Classification System Classification
SAP
•
SAP
Grouping of objects in classes Characteristic value assignment: Describing classified objects in more detail using class characteristics
Use
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⇒ Search for / assign
Only
Internal
objects using classes and characteristics
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Lesson: Classification System
Classification Example
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Internal
SAP
SAP
Figure 28: Classification Example
Characteristic Value Assignment: Example
Only
Internal
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Figure 29: Characteristic Value Assignment: Example
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Object Search: Example
Only
Internal
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Figure 30: Object Search: Example
Object Assignment: Batch Determination Example
Use
SAP
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Figure 31: Object Assignment: Batch Determination Example
You can use the batch determination function to assign batches required for production. The system looks for batches in stock according to user-defined selection criteria and assigns them to the order.
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Lesson: Classification System
You can define the selection conditions for batch determination as characteristic values in classes of class type Batch. You can assign this class either directly to the material component or to a search strategy. The characteristics of a batch are also defined by characteristic values of a class type Batch class. On the basis of the selection conditions and batch classification, the system selects suitable batches in stock and assigns them to the order.
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Lesson Summary You should now be able to: • Create and maintain classes and characteristics
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Internal
SAP
SAP Only
Internal
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Lesson: Classifying Objects for Process Manufacturing
Lesson: Classifying Objects for Process Manufacturing Lesson Overview This lesson introduces you to the main class types for mapping process manufacturing.
Lesson Objectives •
Name the main class types used for process manufacturing and describe their functions
Your company wants to use the Batch Determination and Resource Selection and Reconciliation functions. These functions use the classification system and certain class types.
SAP
SAP
You create the required classes and characteristics with reference to the corresponding class types.
Class Type
•
A class type is the top-level unit of control for classes. Each class must be assigned to exactly one class type. The class type defines, for example:
Internal
– –
The objects that can be classified in a class Whether objects of different object types can be classified in the same class
Only
Sample Class Types Sample Class Types
2005/Q2
Class type
Classifiable objects
001 Material
Materials
023 Batch
Materials, batches, BOM items/reservations
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•
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Business Example
Internal
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After completing this lesson, you will be able to:
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Class type
Classifiable objects
050 Reconciliation
BOM items / reservations
019 Work center class Work centers (=resources)
( ... )
Internal
Only
Planning item (=operations) / order operations ( ... )
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Classifying Objects for Process Manufacturing
SAP
SAP Only
Internal
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Figure 32: Classifying Objects for Process Manufacturing
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Lesson: Classifying Objects for Process Manufacturing
Exercise 6: Classifying Objects for Process Manufacturing Exercise Objectives
Only
Business Example Your company wants to use the Batch Determination and Resource Selection functions. You create the classes and characteristics needed with reference to the class types to be used.
Task:
SAP
1.
SAP
Classification System Display the characteristics M100 and M200. Write down the description and formatting details for these characteristics.
Use
Description
Data type
Unit of measure
M100
Internal
M200 Which status do the characteristics have?
Only
________________ Which type of value assignment has been defined for the characteristics? ________________ Is a value assignment for a classified object required? ________________ Are interval values allowed? ________________ Continued on next page
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Characteristic
Use
Partner
These functions are based on the classification system.
Internal
After completing this exercise, you will be able to: • Create and maintain material characteristic • Create and maintain classes
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Are you allowed to enter negative values? ________________ To which class types is the usage of the characteristics restricted? Tab page Restrictions ________________ ________________
Only
Within which value range are you allowed to assign values to characteristics?
Characteristic
Allowed values
M100 M200
SAP
Display the indicators for one of the characteristics on the Additional Data tab. Use the Field Help (F1) to find out more about the functions of these indicators.
Use
Display the class 023_14 of class type 023 Batch.
Partner
2.
Which description does this class have? _______________
Internal
Which status does this class have? ________________
Only
Which characteristics are assigned to this class? Tab page Characteristics ________________
Continued on next page
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Are you allowed to assign values that have not been defined as allowed values? ________________
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Tab page Values
Internal
________________
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Lesson: Classifying Objects for Process Manufacturing
________________ Hint: During this training course, we will use class 023-14 to classify raw material batches. This is a prerequisite for using the Batch Determination function. 3.
Creating characteristics
Only
Internal
In this exercise, you will create the characteristics M3## and M6## in the classification system. You then assign these characteristics to the class REAC_##, which you first need to create.
Description
Surface coating
Data type
Character format
No. of characters
1
Value assignment
Single value
Use
Partner
a) Create characteristic M3##:
SAP
SAP
Specify that a value must be assigned to the characteristic.
Internal
Characteristic value
Description
G
Glass-coated
P
Polyethylene-coated
S
Stainless steel
Restrict the usage of the characteristics to the class type 019 Work center class.
Only
Save characteristic M3##. b) Create characteristic M6##: Description
Revolutions per minute
Data type
Numeric format
No. of characters
3
Continued on next page
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Partner
Use
Restrict the possible characteristic values in the following way:
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Unit 3: Aspects of the Classification System
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Decimal places
0
Unit of measure
No entry
Value assignment
Single value
Specify that a value must not necessarily be assigned to the characteristic. Interval values are allowed.
Only
Specify that the allowed values are displayed during characteristic value assignment. Restrict the usage of the characteristics to the class type 019 Work center class. 4.
Creating a class Create the class REAC_## of the class type 019 Work center class. Enter 'Reaction vessel' as the description and assign the characteristics M3## and M6##.
SAP Use
Only
Internal
This is a prerequisite for using the Resource Selection function.
Partner
Hint: During the course, the class REAC_## will be used for the classification of resources (reaction vessels).
SAP
Save your class.
Use
Partner
Save the characteristic M6##.
Internal
Enter a possible value range of 0 – 500.
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Lesson: Classifying Objects for Process Manufacturing
Solution 6: Classifying Objects for Process Manufacturing Task: Classification System 1.
Display the characteristics M100 and M200.
Only
Characteristic
Description
Data type
Unit of measure
M100
Partner
M200
Internal
Write down the description and formatting details for these characteristics.
Which status do the characteristics have?
Use
________________ Which type of value assignment has been defined for the characteristics?
SAP
SAP
________________ Is a value assignment for a classified object required? ________________
Use
Partner
Are interval values allowed? ________________ Are you allowed to enter negative values?
Internal
________________ To which class types is the usage of the characteristics restricted?
Only
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Unit 3: Aspects of the Classification System
Characteristic
PLM115
Allowed values
M100 M200 Are you allowed to assign values that have not been defined as allowed values? ________________ Display the indicators for one of the characteristics on the Additional Data tab.
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PLM115
Lesson: Classifying Objects for Process Manufacturing
Use the Field Help (F1) to find out more about the functions of these indicators. SAP Easy Access menu → Cross-Application Components → Classification System → Master Data → Characteristics Characteristic
Description
Data type
Unit of measure
M100
Concentration
Numeric format
%
M200
Density
Numeric format
g/ccm
Which status do the characteristics have? Released
Partner
Which type of value assignment has been defined for the characteristics? Single value Is a value assignment for a classified object required? No
Use
Are interval values allowed? Yes Are you allowed to enter negative values? No To which class types is the usage of the characteristics restricted?
SAP
SAP
Tab page Restrictions 001 = Material class
Use
Tab page Values
Partner
023 = Batch (at client or material level)
Internal
022 = Batch (at plant level) Within which value range are you allowed to assign values to characteristics?
Allowed values
M100
2.0 - 98.0 %
M200
0.5000 - -2.0000 g/ccm
Only
Characteristic
Are you allowed to assign values that have not been defined as allowed values? No (the Additional Values indicator has not been set) 2.
Display the class 023_14 of class type 023 Batch. Continued on next page
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a)
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PLM115
Which description does this class have? _______________ Which status does this class have? ________________ Which characteristics are assigned to this class? Tab page Characteristics
Only
________________
Partner
Hint: During this training course, we will use class 023-14 to classify raw material batches.
Internal
________________
This is a prerequisite for using the Batch Determination function.
Use
a)
SAP Easy Access Menu → Cross-Application Components → Classification System → Master Data → Classes
SAP
SAP
Which description does this class have? Detergent production Which status does this class have? Released Which characteristics are assigned to this class?
Use
M100 concentration M200 density Creating characteristics In this exercise, you will create the characteristics M3## and M6## in the classification system. You then assign these characteristics to the class REAC_##, which you first need to create. a) Create characteristic M3##: Description
Surface coating
Data type
Character format
No. of characters
1
Value assignment
Single value Continued on next page
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Internal
3.
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Tab page Characteristics
PLM115
Lesson: Classifying Objects for Process Manufacturing
Specify that a value must be assigned to the characteristic.
Characteristic value
Description
G
Glass-coated
P
Polyethylene-coated
S
Stainless steel
Restrict the usage of the characteristics to the class type 019 Work center class. Save characteristic M3##.
SAP
Revolutions per minute
Data type
Numeric format
No. of characters
3
Decimal places
0
Unit of measure
No entry
Value assignment
Single value
SAP
Description
Use
Partner
b) Create characteristic M6##:
Use
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Specify that a value must not necessarily be assigned to the characteristic. Interval values are allowed. Enter a possible value range of 0 – 500. Specify that the allowed values are displayed during characteristic value assignment.
Internal
Internal
Only
Restrict the possible characteristic values in the following way:
Restrict the usage of the characteristics to the class type 019 Work center class.
Only
Save the characteristic M6##. a)
Creating characteristics SAP Easy Access menu → Cross-Application Components → Classification System → Master Data → Characteristics
4.
Creating a class Create the class REAC_## of the class type 019 Work center class. Continued on next page
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Unit 3: Aspects of the Classification System
PLM115
Enter 'Reaction vessel' as the description and assign the characteristics M3## and M6##. Save your class. Hint: During the course, the class REAC_## will be used for the classification of resources (reaction vessels).
SAP Easy Access Menu → Cross-Application Components → Classification System → Master Data → Classes
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This is a prerequisite for using the Resource Selection function.
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PLM115
Lesson: Classifying Objects for Process Manufacturing
Lesson Summary You should now be able to: • Name the main class types used for process manufacturing and describe their functions
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Unit Summary
PLM115
Unit Summary You should now be able to: • Create and maintain classes and characteristics • Name the main class types used for process manufacturing and describe their functions
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PLM115
Test Your Knowledge
Describe the task of the class system.
2.
Name the class types used in process manufacturing and the functions for the process order that are based on these.
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1.
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Test Your Knowledge
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Test Your Knowledge
PLM115
Answers 1.
Describe the task of the class system. Answer:
•
Name the class types used in process manufacturing and the functions for the process order that are based on these. Answer:
SAP
Class type 023 batch: batch determination in the process order Class type 019 work center class: resource selection in the process order Class type 050 material reconciliation: reconciliation for material components after process order processing
SAP
• • •
Use
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2.
Classification:grouping of objects in classes Characteristic value assignment:describing classified objects in more detail using class characteristics Search / assignment of objects using classes and characteristics
Internal
Only
• •
Only
Internal
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Unit 4 Internal
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Aspects of Batch Management Unit Overview This chapter introduces fundamental aspects of batch management.
After completing this unit, you will be able to: • •
SAP
•
Use
Only
Internal
Lesson: Batches and Batch Management....................................... 102 Exercise 7: Batches and Batch Management .............................. 109 Lesson: Batch-Specific Material Units of Measure ............................. 118 Exercise 8: Batch-Specific Material Units of Measure..................... 125 Lesson: Batch Levels .............................................................. 133
Partner
Unit Contents
SAP
•
Classify materials in class type Batch Create batch master records and explain characteristic inheritance from material to batch Make basic settings for proportion unit calculation (active ingredient management) Name and explain the available batch levels.
Use
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Unit Objectives
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Unit 4: Aspects of Batch Management
PLM115
Lesson: Batches and Batch Management Lesson Overview This lesson provides an overview of batch management.
Lesson Objectives
Only
Process orders usually use the integration with batch management for their products and material components. Materials that you want to include in batch management must be defined as being subject to batch management requirement.
SAP Use Internal
Batch master record Data record containing the information required for managing a batch. A batch master record is identified by an alphanumeric batch number. You can choose the level at which you want the batch number to be unique in accordance with the structure of your plant and company and your operational requirements.
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Batch Subset of the total quantity of a material held in stock. This subset is managed separately from other subsets of the same material. Quantity of a material produced during a given production run. A batch represents a non-reproducible, homogeneous unit with unique specifications. A production lot can consists of one or more batches. Batches are always uniquely assigned to a material.
Partner
Batch and Batch Master Record: Definition
SAP
To describe the batch properties in more detail, you then classify the relevant materials in a separate class of class type Batch.
Use
Business Example
Classify materials in class type Batch Create batch master records and explain characteristic inheritance from material to batch
Internal
• •
Partner
After completing this lesson, you will be able to:
PLM115
Lesson: Batches and Batch Management
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 client level
•
Internal
Only
Batch Management: Scope of Functions Batch management:
•
Integrated into all applications of the ECC system Supports the management and processing of batches in all business processes of an enterprise Scope of functions:
Partner
SAP Use
Batch number assignment Batch specification (using the classification system) Batch determination Active ingredient management (batch-specific units of measure) Batch derivation Batch record Batch where-used list Batch status management Batch Information Cockpit
SAP
– – – – – – – – –
Use
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– –
Batch management is a function for all industry areas.
• • • • • •
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Chemical industry Pharmaceuticals Food industry Cosmetics Health and hygiene Retail
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Internal
It is of particular importance in the following industry sectors:
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Unit 4: Aspects of Batch Management
PLM115
Batch Management in Supply Chain Mgmt.
Use
In particular, batch management is used in Supply Chain Management. A batch can be followed through the whole supply chain, ranging from the entry of the raw materials to the production of the finished product, and all the way to sales and delivery to the customer. You can assign a batch to a material at various points in the supply chain by creating 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 stock with a batch number and can then be clearly identified.
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Internal
Batch management is integrated with all applications of the ECC system and supports the management and processing of batches in all business processes of an enterprise.
Partner
Some industry sectors, in particular in process industries, need to work with homogenous subsets of a material or product, this means, batches along their entire supply chain.
SAP
SAP
Use
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Only
Internal
Figure 33: Batch Management in Supply Chain Mgmt.
PLM115
Lesson: Batches and Batch Management
If you need a batch with certain specifications in the supply chain, you can find suitable batches from the system in stock using the batch determination function. In production, batch determination is carried out in a process order to find and withdraw suitable material components for the material to be produced.
Material and Batch
Use
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Only
Internal
SAP
SAP
Use
In the ECC system, batch master records depend on the corresponding material master record. Batches are created for a material.
In general, the data of a material master record is valid for all batches assigned to it. In contrast, a batch master record contains 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 class type 023 Batch. 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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The Batch object contains the key fields Material, Batch, and Plant. However, the Plant field is only relevant if the plant level is used as batch level.
Partner
Figure 34: Material and Batch
Unit 4: Aspects of Batch Management
PLM115
You either create a batch master record manually during master data maintenance or the system creates it automatically in the background (for example, when the first goods movement is posted).
Classification of Material and Batch: Characteristic Inheritance
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SAP
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Class type batch specifies a hierarchical relationship between the object types material and batch: When you create a batch for a material, the batch is automatically assigned to the same class of class type batch used to classify the material. This ensures that the same characteristics are used for the material and the batch. In the ECC system, this is called characteristic inheritance. You can define value ranges or fixed values for a characteristic of a class. These specify a maximum value range that applies to all objects assigned to this class, in this case materials and batches.
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Internal
When defining the specifications for batch master records, the higher-level material master records are assigned to classes belonging to class type Batch. In these classes, all material and batch properties are stored as characteristics.
Partner
Figure 35: Classification of Material and Batch: Characteristic Inheritance
PLM115
Lesson: Batches and Batch Management
In the material master record, you can further restrict the values preset by the characteristics. These restrictions are inherited by the batch of the material. You can then only assign values to the characteristics of the batch that lie within the range specified for the material.
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Unit 4: Aspects of Batch Management
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PLM115
Lesson: Batches and Batch Management
Exercise 7: Batches and Batch Management Exercise Objectives
Business Example
Partner
Task 1:
Select view(s):
General plant data/storage 1
Organizational levels:
Plant 1100
Task 2: Classification of materials in the class type 'Batch' 1.
Classify your finished product T-FD1## in class 023_15 'Detergent' of class type 023 'Batch'. Select view(s):
Classification
Class type:
023 'Batch'
Assign the following characteristic value: Continued on next page
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Internal
Check whether the Batch management indicator is set for both the finished product T-FD1## and its raw material T-RD1##.
Partner
Use
1.
SAP
Batch management requirement
To describe the batch properties in more detail, you then classify the relevant materials in a separate class of class type Batch.
Use
Materials that you want to include in batch management must be defined as being subject to batch management requirement.
SAP
Process orders usually use the integration with batch management for their products and material components.
Internal
Only
After completing this exercise, you will be able to: • Classify materials in class type Batch • Create batch master records and explain characteristic inheritance from material to batch
Unit 4: Aspects of Batch Management
Density:
PLM115
1.10 - 1.20 g g/ccm
Save your entry. 2.
Classify your raw material T-RD1## (Sulfuric acid) in the class 023_14 Detergent production of the class type 023 Batch.
Concentration
40 – 60 %
Density
1.30 - 1.50 g/ccm
Internal
Only
Assign the following characteristic values:
Partner
Save your entries.
Task 3: 1.
Use
Creating batches / characteristic inheritance Create the batch master record CH_1 for material T-RD1##. To which class is the batch assigned?
SAP
SAP
________________ Classification tab
Use
Assign the following characteristic values:
Partner
Why?
Internal
Within which value range can you assign values to the characteristics? ______________________________ ______________________________
50 %
Density
1.39 g/ccm
Only
Concentration
Save the batch master record. 2.
Post a goods receipt of 500,000 L of batch CH_1 of material T-RD1## in storage location 0002 of plant 1100. Use movement type 501. Save the goods receipt and then check the stock for material T-RD1##. Continued on next page
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Lesson: Batches and Batch Management
3.
Post another goods receipt (movement type 501) for batch CH_2 of material T-RD1## in storage location 0002 of plant 1100. The system creates the batch master record in the background. Before posting the goods receipt, the system displays the characteristics of the new batch CH_2 for value assignment.
Concentration
40 %
Density
1.30 g/ccm
Internal
Only
Assign the following characteristic values:
Use
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Post your goods receipt.
SAP
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Unit 4: Aspects of Batch Management
PLM115
Solution 7: Batches and Batch Management Task 1: Batch management requirement Check whether the Batch management indicator is set for both the finished product T-FD1## and its raw material T-RD1##. Select view(s):
General plant data/storage 1
Organizational levels:
Plant 1100
(…) → Material → Display → Display Current
Task 2: Classification of materials in the class type 'Batch' Classify your finished product T-FD1## in class 023_15 'Detergent' of class type 023 'Batch'. Select view(s):
Classification
Class type:
023 'Batch'
SAP
SAP
1.
Use
Partner
Assign the following characteristic value: Density:
1.10 - 1.20 g g/ccm
(...) → Material → Change → Immediately Material:
T-FD1##
Select view(s):
Classification
Class type:
023 'Batch'
Class:
023_15
Only
Internal
Save your entry. a)
Assign the characteristic values.
Continued on next page
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Lesson: Batches and Batch Management
2.
Classify your raw material T-RD1## (Sulfuric acid) in the class 023_14 Detergent production of the class type 023 Batch. Assign the following characteristic values: Concentration
40 – 60 %
Density
1.30 - 1.50 g/ccm
Only
(...) → Material → Change → Immediately Material:
T-RD1##
Select view(s):
Classification
Class type:
023 'Batch'
Class:
023_14
Use
Partner
a)
Internal
Save your entries.
Assign the characteristic values.
SAP
SAP
Task 3: Creating batches / characteristic inheritance To which class is the batch assigned?
Within which value range can you assign values to the characteristics?
Partner
Use
Create the batch master record CH_1 for material T-RD1##.
Internal
1.
________________ Classification tab Why?
Only
______________________________ ______________________________ Assign the following characteristic values: Concentration
50 %
Density
1.39 g/ccm
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Unit 4: Aspects of Batch Management
PLM115
Save the batch master record. a)
(…) → Material Master → Batch → Create Material:
T-RD1##
Batch:
CH_1
Classification tab
Only
Within which value range can you assign values to the characteristics? Why? 40 – 60 % 1.3 - 1.5 g/ccm The value ranges of the characteristics are predefined by the classification of the material master.
SAP
Post a goods receipt of 500,000 L of batch CH_1 of material T-RD1## in storage location 0002 of plant 1100. Use movement type 501.
SAP
2.
Use
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Use the input help (F4) on the Values field for the characteristics.
Internal
To which class is the batch assigned? 023_14
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Lesson: Batches and Batch Management
Save the goods receipt and then check the stock for material T-RD1##. a)
Goods receipt for batch created Goods receipt:
Movement type:
501
Plant:
1100
Storage location:
0002
Internal
Only
SAP Easy Access Menu → Logistics → Materials Management → Inventory Management → Goods Movement → Goods Receipt → Other.
Material:
T-RD1##
Quantity:
500,000 l
Batch:
CH_1
Use
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Choose Enter.
Post goods receipt (save) SAP Easy Access Menu → Logistics → Production -Process → Master Data → Material Master → Other → Stock Overview Post another goods receipt (movement type 501) for batch CH_2 of material T-RD1## in storage location 0002 of plant 1100.
Internal
The system creates the batch master record in the background. Before posting the goods receipt, the system displays the characteristics of the new batch CH_2 for value assignment. Assign the following characteristic values: 40 %
Density
1.30 g/ccm
Only
Concentration
Continued on next page
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3.
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SAP
Check stock:
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Unit 4: Aspects of Batch Management
PLM115
Post your goods receipt. a)
Goods receipt for batch not created Goods receipt:
Movement type:
501
Plant:
1100
Storage location:
0002
Internal
Only
SAP Easy Access Menu → Logistics → Materials Management → Inventory Management → Goods Movement → Goods Receipt → Other.
Material:
T-RD1##
Quantity:
500,000 l
Batch:
CH_2
Use
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Choose Enter.
Post goods receipt (save) Assign characteristic values to batch.
SAP
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Internal
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Lesson: Batches and Batch Management
Lesson Summary You should now be able to: • Classify materials in class type Batch • Create batch master records and explain characteristic inheritance from material to batch
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Unit 4: Aspects of Batch Management
PLM115
Lesson: Batch-Specific Material Units of Measure Lesson Overview This lesson introduces you to the maintenance of batch-specific units of measure.
Lesson Objectives •
Make basic settings for proportion unit calculation (active ingredient management)
Partner
Business Example In your company, you use proportion unit calculation (active ingredient management) and make the basic settings for that.
Use
Batch-Specific Material Unit of Measure •
Batch-specific material unit
SAP
Batch-specific material units of measure are:
Use
You use batch-specific units of measure when the ratio for conversion from the unit of measure into the base unit of measure can differ from batch to batch. Proportion unit: Unit of measure in which proportion quantities of a material can be entered. The total or physical quantity can consist of several proportions. Product unit of measure: Unit of measure that describes the total quantity of a material. Used as an alternative to the base unit of measure.
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Internal
Proportion units and product units of measure for materials that are subject to batch management requirement can be used in all processes in the supply chain.
Partner
Proportion unit Product unit of measure
SAP
An alternative unit of measure of a material, for which you can define the conversion ratio into the base unit of measure on a batch-specific basis. – –
Internal
Only
After completing this lesson, you will be able to:
PLM115
Lesson: Batch-Specific Material Units of Measure
While the conversion ratio for non-batch specific alternative units of measure is not specified in the base unit of measure in the material, for proportion units and product units of measure, you define • •
The planned conversion ratio in the material The actual conversion ration in the batch
Only
Use
Partner
Proportion Unit Calculation (Active Ingredient Quantities)
Internal
As long as the batch is not known, the system uses the planned conversion ratio from the material when converting to the base quantity. As soon as the batch is known, the system uses the actual conversion ratio from the batch.
SAP
SAP
Internal
Use
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Figure 36: Proportion Unit Calculation (Active Ingredient Quantities)
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Example: Using Proportion Quantities in the Master Recipe
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Figure 37: Example: Using Proportion Quantities in the Master Recipe
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Lesson: Batch-Specific Material Units of Measure
Batch-Specific Material Units of Measure: Customizing
SAP
SAP
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Figure 38: Batch-Specific Material Units of Measure: Customizing
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Unit 4: Aspects of Batch Management
PLM115
Batch-Specific Material Units of Measure: Master Data Maintenance
SAP
SAP
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Figure 39: Batch-Specific Material Units of Measure: Master Data Maintenance
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Lesson: Batch-Specific Material Units of Measure
Material Master Classification
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Active ingredient characteristics are assigned the special view 'S' within the batch class.
Use
Only
Internal
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Characteristics with this view are recognized when you maintain the material master. The information for conversion between active ingredient and physical quantity is transferred to the material master.
SAP
SAP
Figure 40: Material Master Classification
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PLM115
Maintaining Units of Measure in the Material Master
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Figure 41: Maintaining Units of Measure in the Material Master
SAP Use
The planned value specifies the expected mixing ratio between active ingredient and physical quantity in the characteristic unit of measurement.
•
124
If the actual proportion of active ingredient in a batch is not known for a particular business transaction, the system uses the planned value from the material master. The planned value for the conversion between active ingredient and physical quantity is transferred to the units of measure table automatically.
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•
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You must then complete the information in the Proportion/Product Unit of Measure view: The system expects a planned value for the active ingredient proportion.
SAP
When you have maintained the Classification view, the system knows possible active ingredient characteristics and you can select them in the Proportion/product unit of measure view and assign them to a suitable proportion unit if required.
PLM115
Lesson: Batch-Specific Material Units of Measure
Exercise 8: Batch-Specific Material Units of Measure Exercise Objectives
Business Example
Task: Settings for active ingredient management Settings for active ingredient managementMaterial Fruit premix T-RJ1## contains the proportion units (active ingredients) Fruit Content and Acid Content.
SAP
Check whether suitable units of measure have been defined. What are the descriptions for the following units of measure? LF = _________________________________
2.
Make sure that the use of batch-specific units of measure is activated!
3.
To which unit of measure are the batch-specific units of measurement LF and LA referenced?
4.
Take a look at the definition of the characteristic unit of measure % for proportion calculation. Note that in the case of percentage proportion calculation the units of measure are defined independent of the batch-specific units of measure and base units of measure. Afterwards, take a look at, for example, the definition of the characteristic unit of measure LIL. What are the batch-specific units of measure and the base units of measure from which it is calculated? Continued on next page
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Internal
LA = _________________________________
Partner
Use
1.
SAP
As an alternative to the base unit of measure, you also want to use batch-specific material units of measure in your different applications.
Use
Partner
In addition, you make the basic settings for proportion quantity calculation (active ingredient management) for some of your materials.
Internal
Only
After completing this exercise, you will be able to: • Make basic settings for proportion unit calculation (active ingredient management)
Unit 4: Aspects of Batch Management
PLM115
LIL = __________________________________________ 5.
Display the material master record of the material Fruit Premix T-RJ1##. Which data is maintained in the classification view?
Material:
Class:
Characteristic value:
Characteristic value:
Fruit content
Acid content
Partner
6.
Check whether the application view S is maintained in the basic data and in the characteristics in the classes found under 5-4-5. Display the class from the material master of the raw material T-RJ1##.
7.
What are the characteristic names that belong to the characteristic descriptions fruit content and acid content?
Internal
Only
T-RJ1##
Fruit content = ____________________________ Check whether the characteristics mentioned in 7-4-7 have the following settings:
SAP
SAP
8.
The status is released. The data type is numeric.
Use
Which unit of measure is maintained for these two characteristics? ____________________ Navigate to the Proportion/Product Unit view. With reference to which batch characteristic was a conversion of the base unit of measure to the proportion unit defined? ____________________ To which proportion unit is the base unit of measure converted? ___________________ Which planned value is used for conversion as long as no concrete batch is known? ____________________ Finally, navigate to the Units of Measure view in the additional data. 10. a) In change mode, navigate to the Additional Data of your material T-RJ1##. Continued on next page
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Internal
Navigate to the Additional Data in the material master of material T-RJ1##.
Partner
The value assignment is a single value and no negative values are allowed.
9.
Use
Acid content = ____________________________
PLM115
Lesson: Batch-Specific Material Units of Measure
Navigate to the Proportion/Product Unit view. Use the additional characteristic M900 acid content to also define the use of the proportion unit LA. The planned value is to be 3 %. Save your settings.
Carry out the different analyses regarding the batch characteristics Fruit Content and Acid Content.
Partner
c) Display the batch stocks in the stock overview for the units of measure L, LF and LA. Compare stock quantities with the corresponding characteristic values.
Internal
Only
b) Post the goods receipts for several batches for material T-RJ1## to warehouse 0002 of plant 1100.
Use
SAP
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Use
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Unit 4: Aspects of Batch Management
PLM115
Solution 8: Batch-Specific Material Units of Measure Task: Settings for active ingredient management
As an alternative to the base unit of measure, you also want to use batch-specific material units of measure in your different applications. Check whether suitable units of measure have been defined. What are the descriptions for the following units of measure? LF = _________________________________ LA = _________________________________ a)
Tools → Customizing → IMG → Execute Project / SAP Reference IMG /
SAP
Units of Measure (without dimensions) LF = L fruit
Use
2.
Make sure that the use of batch-specific units of measure is activated!
3.
(…) → SAP Customizing Implementation Guide → Logistics - General → Batch Management → Batch-Specific Material Units of Measure → Activate Batch-Specific Units of Measure
To which unit of measure are the batch-specific units of measurement LF and LA referenced? a)
(…) → SAP Customizing Implementation Guide → Logistics - General → Batch Management → Batch-Specific Material Units of Measure → Edit Batch-Specific Units of Measure Both batch-specific units of measure have the Liter as their reference unit of measure.
4.
Take a look at the definition of the characteristic unit of measure % for proportion calculation. Continued on next page
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a)
Partner
LA = L Acid
SAP
SAP Customizing Implementation Guide → General Settings → SAP Netweaver → Check Units of Measure/
Use
Partner
1.
Internal
Only
Settings for active ingredient managementMaterial Fruit premix T-RJ1## contains the proportion units (active ingredients) Fruit Content and Acid Content.
PLM115
Lesson: Batch-Specific Material Units of Measure
Note that in the case of percentage proportion calculation the units of measure are defined independent of the batch-specific units of measure and base units of measure. Afterwards, take a look at, for example, the definition of the characteristic unit of measure LIL. What are the batch-specific units of measure and the base units of measure from which it is calculated? LIL = __________________________________________
Only
(…) → SAP Customizing Implementation Guide → Logistics - General → Batch Management → Batch-Specific Material Units of Measure → Calculate Proportional Factors → Define Percentage Calculation
LIL = LI1 Liter Active ingredient 1/ L Liter Display the material master record of the material Fruit Premix T-RJ1##. Which data is maintained in the classification view?
Material:
Class:
Characteristic value:
Characteristic value:
Fruit content
Acid content
SAP
SAP
5.
Use
Partner
(…) SAP Customizing Implementation Guide → Logistics - General → Batch Management → Batch-Specific Material Units of Measure → Calculate Proportional Factors → Define Calculation of Proportion Quantity from Base Quantity
Internal
a)
a)
SAP Easy Access menu: Logistics → Production -Process → Master Data → Material Master → Material → Display → Display Current
Internal
Classification view Characteristic value: Characteristic value: Class:
Fruit content
Acid content
T-RJ1##
023_20
80 – 100 %
3–5%
Only
Material:
Continued on next page
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T-RJ1##
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Unit 4: Aspects of Batch Management
6.
PLM115
Check whether the application view S is maintained in the basic data and in the characteristics in the classes found under 5-4-5. Display the class from the material master of the raw material T-RJ1##. a)
Material master T-RJ1## Classification view Position the cursor on the class entry Basic data and Characteristics tab pages Both the class and the characteristics are maintained for application view S.
Partner
7.
What are the characteristic names that belong to the characteristic descriptions fruit content and acid content? Fruit content = ____________________________ a)
Use
Acid content = ____________________________ In the class master record: Characteristics tab page
SAP
SAP
Fruit content = M800 Acid content = M900 Check whether the characteristics mentioned in 7-4-7 have the following settings: The status is released.
Internal
The data type is numeric. The value assignment is a single value and no negative values are allowed. Which unit of measure is maintained for these two characteristics?
Only
____________________ a)
In the class master record: Characteristics tab page Double-click the characteristic. Characteristics M800 and M900 are both released, numeric, and have a single value. Negative values are not allowed. For both characteristics, the unit of measure % (percent) is maintained. Continued on next page
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Use
8.
Internal
Only
Environment → Display Master Data
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PLM115
Lesson: Batch-Specific Material Units of Measure
9.
Navigate to the Additional Data in the material master of material T-RJ1##. Navigate to the Proportion/Product Unit view. With reference to which batch characteristic was a conversion of the base unit of measure to the proportion unit defined? ____________________ To which proportion unit is the base unit of measure converted? ___________________
Only
Finally, navigate to the Units of Measure view in the additional data. With reference to which batch characteristic was a conversion of the base unit of measure to the proportion unit defined? M800 Fruit Content To which proportion unit is the base unit of measure converted? LF Liter Fruit
SAP
85 % 10. a) In change mode, navigate to the Additional Data of your material T-RJ1##.
Use
Use the additional characteristic M900 acid content to also define the use of the proportion unit LA. Save your settings. b) Post the goods receipts for several batches for material T-RJ1## to warehouse 0002 of plant 1100. Carry out the different analyses regarding the batch characteristics Fruit Content and Acid Content. c) Display the batch stocks in the stock overview for the units of measure L, LF and LA. Compare stock quantities with the corresponding characteristic values. a)
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Task no 10 to a-c is an exercise description; use the usual approach
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Internal
The planned value is to be 3 %.
Partner
Navigate to the Proportion/Product Unit view.
SAP
Which planned value is used for conversion as long as no concrete batch is known?
Use
Partner
a)
Internal
Which planned value is used for conversion as long as no concrete batch is known? ____________________
Unit 4: Aspects of Batch Management
PLM115
Lesson Summary You should now be able to: • Make basic settings for proportion unit calculation (active ingredient management)
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Internal
SAP
SAP Only
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Use
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PLM115
Lesson: Batch Levels
Lesson: Batch Levels Lesson Overview This lesson introduces you to the batch levels that are available.
Lesson Objectives •
Name and explain the available batch levels.
Business Example
You must choose the level at which level you want the batch number to be unique in accordance with the structure of your plant and company and your operational requirements.
SAP
SAP
Levels of Uniqueness of a Batch
Use
Partner
In Customizing, you can choose the organizational validity area of the batches. Three batch levels are available.
Internal
Only
After completing this lesson, you will be able to:
Only
Internal
Use
Partner
Figure 42: Levels of Uniqueness of a Batch
A material master record is identified by an alphanumeric material number. This material number is unique at the client level.
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Unit 4: Aspects of Batch Management
PLM115
A batch master record is identified by an alphanumeric batch number. You can choose the level at which you want the batch number to be unique in accordance with the structure of your plant and company and your operational requirements.
Changing Batch Levels
Use
Only
Internal
You can change to a higher level at any time. However, if you want to change to a lower level, the system only lets you change from the material level to the client level. You cannot change to the plant level. This is due to the organization of the batch data, which must be converted each time you change the batch level.
Partner
You can select the validity of the batch in Customizing. Three batch levels are available. The default setting in the standard system is the plant level.
SAP
SAP
Use
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Only
Internal
Figure 43: Changing Batch Levels
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PLM115
Lesson: Batch Levels
Converting Batch Numbers
Use
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Only
Internal
Use
You can use the conversion tool to display the current state of conversion. The system repeats the checks again and again to find out if the existing batch numbers are unique at the new level. Use the test mode. If the numbers are unique, you can carry out conversion.
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When converting existing batch data, the system checks whether identical batch numbers exist. If all batch numbers are unique at the new level (that is, the material level), the batch number can be converted directly. If they are not unique, the system writes a log containing all batch numbers that cannot be converted. You have to decide which batch numbers remain valid and which have to be posted to new batches together with their stock. If you want the system to delete batches, you must set the deletion flag and start a batch reorganization run.
Partner
Up to now, you could issue the same batch number for one material number in each plant. The batches did not need to be identical, since they were completely independent of each other. In this example, we assume that the batch specifications are completely different.
Internal
If the batch number was unique at the plant level up to now, and you want to change the validity so that it is unique only at the material level, you must convert the batch numbers when you make this change.
SAP
SAP
Figure 44: Converting Batch Numbers
Unit 4: Aspects of Batch Management
PLM115
At the new batch level, the batch number is unique for each material and is no longer additionally distinguished by the plant.
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SAP
SAP Only
Internal
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Lesson: Batch Levels
Lesson Summary You should now be able to: • Name and explain the available batch levels.
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SAP
SAP Only
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Unit Summary
PLM115
Unit Summary
Only
Use
Partner
Internal
You should now be able to: • Classify materials in class type Batch • Create batch master records and explain characteristic inheritance from material to batch • Make basic settings for proportion unit calculation (active ingredient management) • Name and explain the available batch levels.
SAP
SAP Only
Internal
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Test Your Knowledge
Partner
Name some items of the scope of functions of batch management
2.
When do you use batch-specific material units of measure?
3.
At which organizational levels can you define the uniqueness of the batch number?
Use
1.
Internal
Only
Test Your Knowledge
SAP
SAP Only
Internal
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Test Your Knowledge
PLM115
Answers 1.
Name some items of the scope of functions of batch management Answer:
Only Partner
Use
2.
Batch number assignment Batch specification (using the classification system) Batch determination Active ingredient management (batch-specific units of measure) Batch derivation Batch record Batch where-used list Batch status management Batch Information Cockpit
Internal
• • • • • • • • •
When do you use batch-specific material units of measure?
SAP Use
At which organizational levels can you define the uniqueness of the batch number? Answer:
Internal
140
Client level Material level Plant level
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• • •
Partner
3.
SAP
Answer: You use batch-specific material units of measure when the ratio for conversion from the unit of measure into the base unit of measure can differ from batch to batch.
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Unit 5 Internal
Only
Resources Unit Overview This chapter introduces you to resource master records.
Partner
Unit Objectives After completing this unit, you will be able to:
SAP
Explain the structure of a resource master record. Maintain available capacities Create formulas and assign them in resource master records. Create resources Make the basic Customizing settings for resources Create resource networks Classify resources for system-aided resource selection Carry out reporting for resources
SAP
Lesson: Resources: Overview .................................................... 142 Exercise 9: Resources: Overview............................................ 147 Lesson: Capacities ................................................................. 153 Lesson: Formulas................................................................... 157 Lesson: Creating Resources and Further Maintenance Activities............ 162 Exercise 10: Creating Resources and Further Maintenance Activities.. 169
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Unit Contents
Partner
Use
Use
• • • • • • • •
Unit 5: Resources
PLM115
Lesson: Resources: Overview Lesson Overview This lesson provides an overview of resource master records.
Lesson Objectives •
Explain the structure of a resource master record.
Business Example
Partner
You have to map the means of production in your company in the form of resource master records.
Use
First, get an overview of the structure of resource master records.
Internal
Only
After completing this lesson, you will be able to:
Resources
SAP
SAP Only
Internal
Use
Partner
Figure 45: Resources
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Lesson: Resources: Overview
Resources are the main planning instruments of production planning and control. The data you maintain for a resource is, for example, used for: • • •
Scheduling process orders Capacity requirements planning Product and order costing
Internal
Only
Resources are grouped in resource categories on the basis of their usage and function. You can define your own resource categories in Customizing.
Use
Partner
Resources in Recipes or Process Orders
SAP
SAP
Operations describe the different steps required during the production process. For a more detailed description of these steps, phases are assigned to the operations. Exactly one resource is assigned to an operation. This assignment of the resource is also valid for all phases that belong to the operation. Usually a master recipe is used to create a process order. The operation and phase structure together with its relationships and assigned resources as well as material components and process instructions are copied to the process order.
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Figure 46: Resources in Recipes or Process Orders
Unit 5: Resources
PLM115
Resource Data I
You can find resource-related data on several screens. The graphic shows some of the most important resource data.
SAP Use Internal
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You can enter default values for the phase to be executed at a resource. When you maintain the phases and operations in the master recipe or process order, the system copies or references this information. You can, for instance, propose a control key. A control key specifies how a phase or an operation is to be processed from a business point of view.
Partner
By entering a standard value key, you assign possible standard values to a resource for the phases in process orders to be executed at this resource. A standard value is a planned value used to carry out a phase, such as the execution time. Standard values are used in costing, scheduling, and capacity requirements planning to calculate costs, execution times, and capacity requirements.
SAP
On the Basic Data screen, you define a person or group of persons responsible for the maintenance of the master data of this resource. By defining the task list usage, you also specify the task list types (such as master recipe, equipment task list, or inspection plans) in which the resource can be used and whether the resource can be used in orders.
Use
Partner
Only
Internal
Figure 47: Resource Data I
PLM115
Lesson: Resources: Overview
Resource Data II
Use
Partner
Only
Internal
Available capacities of resources are the basis for scheduling process orders. They are also required for capacity requirements planning and shop floor control.
Use
To calculate costs, execution times and capacity requirements of phases carried out at a resource, enter a formula key that refers to a suitable formula on the corresponding screens of the resource.
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Internal
By assigning a cost center to a resource, you link the resource to cost accounting and can now carry out product and order costing. You can define the specific output of a resource by assigning activity types, which are defined for the cost center.
Partner
In order to calculate the execution time of an operation during process order scheduling, the available capacity of exactly one of several possible resource capacities is defined as the basis for scheduling.
SAP
SAP
Figure 48: Resource Data II
Unit 5: Resources
PLM115
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Internal
SAP
SAP Only
Internal
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PLM115
Lesson: Resources: Overview
Exercise 9: Resources: Overview Exercise Objectives After completing this exercise, you will be able to: • Explain the structure of a resource master record.
You are to get an overview of the data of a resource master record.
Task: To get a general overview of the screens and fields of a resource, look through those for resource T-IC1## for plant 1100. Write down the corresponding entries. Use F1 and F4 help to find out more about the meaning, functions, and entry options for individual data fields. 1.
SAP
Resource data overview
SAP
2.
Basic data tab Description
Use
Partner
Resource category Person responsible Task list usage
Internal
Standard value key Assigned default value
Only
3.
Defaults tab Control key Unit of measure of standard values
4.
'Capacities' tab
Continued on next page
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Use
Partner
Resource data overview
Internal
Only
Business Example
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Unit 5: Resources
PLM115
Capacity category Internal processing requirements formula (Assigned formula for capacity requirements determination) 5.
'Scheduling' tab
Only
Internal
Capacity category
Partner
Formula key for in-house processing duration
6.
Use
(Assigned formula for calculating the phase duration) Costing tab
SAP
Formula key
SAP
Controlling area
Use
Validity Cost center Activity type
Only
Internal
From the resource menu, go to the Application Help. Familiarize yourself with the information available on resources in the documentation.
Partner
(Assigned formula for activity calculation regarding the default value)
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Lesson: Resources: Overview
Solution 9: Resources: Overview Task: Resource data overview To get a general overview of the screens and fields of a resource, look through those for resource T-IC1## for plant 1100. Write down the corresponding entries.
Only
1.
Resource data overview a)
Partner
2.
(…) → Resources → Resource → Display
Basic data tab
Internal
Use F1 and F4 help to find out more about the meaning, functions, and entry options for individual data fields.
Description
Use
Resource category Person responsible Task list usage
SAP
SAP
Standard value key Assigned default value
Use Internal
Description
Mixing tank
Resource category
0008
Person responsible
I##
Task list usage
PI2
Standard value key
SAP8
Assigned default value
Duration, fixed
Only
3.
Partner
a)
Defaults tab
Continued on next page
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Unit 5: Resources
PLM115
Control key Unit of measure of standard values
4.
Control key
PI01
Unit of measure of standard values
MIN
Internal
Only
a)
'Capacities' tab
Partner
Capacity category Internal processing requirements formula
Use
(Assigned formula for capacity requirements determination)
Use
008
Internal processing requirements formula
SAPL61
Partner
5.
Capacity category
SAP
SAP
a)
'Scheduling' tab
Internal
Capacity category
Only
Formula key for in-house processing duration
Continued on next page
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Lesson: Resources: Overview
(Assigned formula for calculating the phase duration) a)
Only
008
Formula key for in-house processing duration
SAPL61
Costing tab
Internal
6.
Capacity category
Validity Controlling area
Partner
Cost center Activity type
Use
Formula key (Assigned formula for activity calculation regarding the default value)
01.01.1998 – 31.12.9999
Controlling area
1000
Cost center
4271
Activity type
1420
Formula key
SAPL61
SAP
Only
Internal
Validity
Partner
Use
a)
SAP
From the resource menu, go to the Application Help. Familiarize yourself with the information available on resources in the documentation.
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Unit 5: Resources
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Lesson Summary You should now be able to: • Explain the structure of a resource master record.
Use
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Internal
SAP
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Lesson: Capacities
Lesson: Capacities Lesson Overview This lesson introduces you to the maintenance of capacity data.
Lesson Objectives •
Internal
Only
After completing this lesson, you will be able to: Maintain available capacities
Business Example
Partner
To map the time-based availability of resources, you have to maintain available capacities.
Use
Capacities and Capacity Categories
SAP
SAP Only
Internal
Use
Partner
Figure 49: Capacities and Capacity Categories
Together with the available capacity and capacity loads collected for them, capacities are the central planning unit for capacity requirements planning.
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Unit 5: Resources
PLM115
You can assign any number of capacities of different capacity categories to one resource. A capacity category is a description that classifies capacities and can be defined by the user in Customizing. Capacity categories are, for example, machine capacities, labor capacities, and energy.
Maintaining Available Capacities
Use
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SAP
SAP
Use
You create the available capacity that is to apply to only one specific resource as a resource capacity in the resource itself. Capacities that are used by several capacities, such as a common steam reservoir or the clean-out team, are created as pooled capacities and assigned to the resources. When creating an available capacity, you can copy or reference capacities of different origins (for central maintenance of available capacities). In Customizing, you can create default available capacities per plant and capacity category whose data is then set as default values when the corresponding capacity is created.
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Internal
You can maintain variable availability in time for each capacity. The available capacity is the ability of a capacity to perform a specific task in a certain period of time.
Partner
Figure 50: Maintaining Available Capacities
PLM115
Lesson: Capacities
The available capacity is determined using work start and finish times, break times, rate of capacity utilization, and the number of individual capacities. Different available capacities of a capacity category are identified using the version number. The version of the available capacity that appears in the screen header as the active version is used during capacity requirements planning and scheduling.
Maintaining Avail. Capacity Using Shift Sequences
Use
Partner
Only
Internal
SAP
SAP
Use
You can use shift sequences to reduce the time and effort needed to maintain an available capacity.
In a shift sequence, you maintain the sequence of certain shift definitions for several resources. You define shift sequences in Customizing.
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Internal
In a shift definition, you define the work start and finish times as well as duration of breaks, which are valid for several resources.
Partner
Figure 51: Maintaining Avail. Capacity Using Shift Sequences
Unit 5: Resources
PLM115
Lesson Summary You should now be able to: • Maintain available capacities
Use
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Only
Internal
SAP
SAP Only
Internal
Use
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PLM115
Lesson: Formulas
Lesson: Formulas Lesson Overview This lesson introduces you to there maintenance and the use of formulas for resources.
Lesson Objectives •
Create formulas and assign them in resource master records.
Business Example
Partner
You have to assign formulas to your resources to control time scheduling, capacity requirements planning and to determine costs in process orders.
Use
Formulas in the Resource
Internal
Only
After completing this lesson, you will be able to:
SAP
SAP
To calculate costs, execution times and capacity requirements of phases carried out at a resource, enter a formula key that refers to a suitable formula on the corresponding screens of the resource.
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Internal
Use
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Figure 52: Formulas in the Resource
Unit 5: Resources
PLM115
Formula Parameters and Formula
Use
Partner
Only
Internal
Figure 53: Formula Parameters and Formula
SAP
Formula parameters that you can use include standard values, constants defined in the resource (for example, resource output) as well as general operation values in master recipes or process orders (for example, operation quantity).
SAP
Formulas and formula parameters are defined in Customizing.
Only
Internal
Use
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Lesson: Formulas
Duration and Capacity Requirement of a Phase
Use
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Only
Internal
SAP
To calculate the duration, you must specify a capacity category as a basis for scheduling and define a formula in the resource.
Scheduling and determination of capacity requirements takes place at phase level. The operation dates and capacity requirements of operations are derived from the phase.
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Internal
When calculating the phase dates, the available capacity of the scheduling basis including breaks is taken into account.
Partner
Use
On the basis of the standard values and other formula parameters (see graphic), formulas are used to calculate the duration and capacity requirements (per capacity category) of a phase.
SAP
Figure 54: Duration and Capacity Requirement of a Phase
Unit 5: Resources
PLM115
Production Costs per Phase
Use
Partner
Only
Internal
The costs incurred due to the use of a resource in a phase must be calculated in production and order costing. For this, you must maintain costing data in the resource.
Use
For a specified validity period, you can assign a resource to one cost center only.
The output of a resource is calculated for each default value and activity type with the help of formulas. Finally, the costs are calculated using the output of a resource and the corresponding prices.
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To calculate the costs, activity types specified in the cost centers are assigned to the resource for each default value. Each activity type is valued with specific price.
Partner
The link to cost accounting is created by assigning a cost center to a resource.
SAP
SAP
Figure 55: Production Costs per Phase
PLM115
Lesson: Formulas
Lesson Summary You should now be able to: • Create formulas and assign them in resource master records.
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SAP
SAP Only
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Unit 5: Resources
PLM115
Lesson: Creating Resources and Further Maintenance Activities Lesson Overview
Internal
Only
In this lesson you will learn how resource master records are created and managed. Furthermore, you will learn about important Customizing settings for resource management
Lesson Objectives After completing this lesson, you will be able to:
Partner
Create resources Make the basic Customizing settings for resources Create resource networks Classify resources for system-aided resource selection Carry out reporting for resources
Use
• • • • •
SAP
You use resource master records to map your company's means of production onto the SAP ECC System.
Use Internal
You will then maintain the resource data, which means that you maintain, for example, available capacities and assign formulas to be able to carry out scheduling and capacity planning, and determine costs for the process order. Further activities include creating resource networks and classifying resources for the purpose of system-aided resource selection.
Partner
First, you will make the necessary basic Customizing settings.
SAP
Business Example
Only
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Lesson: Creating Resources and Further Maintenance Activities
Creating a resource
Use
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Only
Internal
Figure 56: Creating a resource
SAP
Only
Internal
Partner
•
Manually Using a default resource that is defined in Customizing per plant and resource category. Its data is used as default values when a corresponding resource is created. By copying a resource that already exists
SAP
• •
Use
You can create a resource in PP-PI in the following ways:
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Unit 5: Resources
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Customizing: Basic Settings
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Internal SAP
SAP
Figure 57: Customizing: Basic Settings
Functions of the Resource Category
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Internal
Use
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Figure 58: Functions of the Resource Category
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Lesson: Creating Resources and Further Maintenance Activities
Resources are grouped in resource categories on the basis of their usage and function. You can define your own resource categories in Customizing. Resource categories have the following functions:
•
Partner
•
Each resource category is assigned one or more task list types in Customizing. A task list application groups one or more task list types. This assignment specifies the task list types for which a resource of a certain category can be used. Task list types are, for instance, master recipes, maintenance task lists, inspection plans. In PP-PI, the task list type "master recipes" is used. In Customizing, you can maintain a default resource for each resource category and plant. When you create a resource, the data maintained for the default resource is transferred to this resource as default values. In Customizing, you can define the screen sequence and field selection for resource maintenance for each resource category.
Use
Field Selection
Internal
Only
•
SAP
SAP Only
Internal
Use
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Figure 59: Field Selection
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Unit 5: Resources
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In Customizing for Resources, you can use field selection to influence the attributes of individual fields shown on the resource maintenance screens. You can specify how specific data fields are displayed. You have the following options for data fields:
Only
Input field Required input field Display field The field is hidden. The field is highlighted.
You can specify the field display for all resource categories for each screen group and then change it later for certain resource categories.
Use
Partner
Resource Network
Internal
• • • • •
SAP
SAP
You can often use processing units in a specified sequence only. Predecessor and To map this onto the system, you can create predecessor/successor relationships between resources in the form of resource networks. If several similar resources are available in a network, it makes sense to decide on the resource to be used at the time of production and not before. To do this, you can use the task list usage to define a resource that is to be used for planning purposes only. This resource represents several equivalent resources.
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Figure 60: Resource Network
PLM115
Lesson: Creating Resources and Further Maintenance Activities
In Customizing, you can set the Until release indicator for a task list usage. If a process order is assigned a resource whose usage is restricted in this way, the order cannot be released. Before releasing the order, you must replace the planning resource with a suitable individual resource. You can use the function of resource selection to do so.
Classification of Resources
SAP
SAP
Use
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Only
Internal
Figure 61: Classification of Resources
Use
The characteristic values of classified operations represent the selection criteria for system-aided resource selection in the process order. This enables the selection of a suitable resource just before production begins. The resource network can be taken into account for resource selection.
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Internal
Apart from resources, you can also classify operations of master recipes (or process orders) in classes of class type 019. This allows you to store specifications for a resource in an operation.
Partner
You can add specific resource attributes to the resource data by classifying the resource with classes of class type 019 Work center class. The resource attributes are stored as characteristics of a class and are assigned specific values in the resources.
Unit 5: Resources
PLM115
Reporting Functions for Resources
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SAP
SAP
Figure 62: Reporting Functions for Resources
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Internal
Use
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Lesson: Creating Resources and Further Maintenance Activities
Exercise 10: Creating Resources and Further Maintenance Activities Exercise Objectives
Only
Business Example You use resource master records to map your company's means of production onto the SAP ECC System.
Use
Partner
Internal
After completing this exercise, you will be able to: • Create and maintain resources • Maintain available capacities • Make the basic Customizing settings for resources • Create resource networks • Classify resources for system-aided resource selection • Carry out reporting for resources
First, you will make the necessary basic Customizing settings.
SAP Use
Task 1: In this exercise, you will become familiar with the most important Customizing settings for resources. Documentation is available for the individual Customizing activities, which you can display if you need help when making Customizing settings. Furthermore, you can use the F1 and F4 help for data maintenance. 1.
Basic Customizing settings for resources
2.
Defining a resource category Define the resource category RE## "Processing unit group". ##'. Reference to the field selection and the screen sequence of the existing resource category 0008. Continued on next page
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Internal
Basic Customizing settings for resources
Partner
Further activities include creating resource networks and classifying resources for the purpose of system-aided resource selection.
SAP
You will then maintain the resource data, which means that you maintain, for example, available capacities and assign formulas to be able to carry out scheduling and capacity planning, and determine costs in the process order.
Unit 5: Resources
PLM115
Specify that change documents are to be written for the resources of the category RE##. Assign the task list usage for recipes to the resource category RE##. 3.
Defining a person responsible for a resource Define the person responsible R## "Person responsible for resource group##" for plant 1100.
Restrict the task list usage ## Until order release.
Assign the task list type “Master recipe” to both task list usages. 5.
Defining a control key Define control key K1## "Cost., Sched., Capa. Grp.##" and K2## "Cost., Sched., Capa., QM Grp.##'".
SAP
For control key K2##, also set the Inspection Characteristics Required indicator. Confirmation for phases with these control keys should be possible.
Use
Defining the field selection Which field groups of the basic data screen group are defined as required entries for resource category 0008?
Task 2: Data on capacity requirements planning 1.
Creating capacity categories Create the capacity category M## "Processing unit##" and P## "Personnel Group##". Define capacity category P## as a Labor capacity. Which function is made possible by setting the CapCatPers indicator? ______________________________________________ Continued on next page
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_______________________ and _______________________
Partner
6.
SAP
Set the Scheduling indicator, Capacity Requirements indicator, and Cost indicator for both control keys.
Use
Define the task list usages O## "Recipe & Order group##" and C## "Recipe until release, group##".
Internal
Only
Defining a task list usage
Partner
4.
PLM115
Lesson: Creating Resources and Further Maintenance Activities
______________________________________________ Save your entries. 2.
Defining an area of responsibility for capacity requirements planning. Define the responsible capacity requirements planner group C## "Cap. planner grp.##".
3.
Defining default capacities
Only
Planner group
C##
Factory calendar ID
01
Base unit of measure
H
Standard avail. capacity
Start: 00:00:00
Use
Partner
Define the following default values for both capacity categories:
100
No. Single cap.
1
Use
Task 3:
Internal
Creating formulas for resources 1.
Defining formula parameters
Only
Define the following formula parameters:
Continued on next page
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The capacity categories are to be relevant for finite scheduling. This means that the available capacity is taken into account during capacity requirements planning.
SAP
SAP
Finish: 24:00:00 Capacity utilization
Internal
Define default capacities for the capacity categories M## and P## in plant 1100.
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Param.
Origin
Key words
Dim.
Std value
Std value unit
DF##
2
Duration, fixed
TIME
H
DV##
2
Duration, variable
TIME
H
Field name
Base quantity
1
BMSCH
PHQU##
Phase qty
1
MGVRG
Hint: The parameters DF## and DV## are the standard values for a phase.
SAP
2.
Defining a standard value key
Use Internal
Also set the Generate indicator. You use this indicator to control whether a coding command is generated for a standard value. 3.
Defining formula keys
Partner
Define the standard value key SK## "Fixed and variable time group##" and assign the standard values DF## and DV## to it.
SAP
The parameters BAQU## and PHQU## are general operation values of the recipe or process order. The operation values are transferred to the formula parameters by way of their field names.
Use
Partner
BAQU##
Internal
Only
Unit 5: Resources
Define the following formulas:
Only
Formula
Description
Formula definition
FIX##
Duration, fixed
DF##
VAR##
Duration, qty-dep.
DV## * PHQU## / BAQU##
DUR##
Total duration
DF## +DV## * PHQU## / BAQU##
Set the Generate indicator for each one. Continued on next page
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Lesson: Creating Resources and Further Maintenance Activities
Also allow the use of the formula for costing, capacity requirements planning, and scheduling.
Task 4: Creating a resource 1.
Defining a default resource
Internal
Only
Define a default resource for resource category RE## in plant 1100.
Description
Resource
Person responsible
R##
Task list usage
O##
Standard value key
SK##
Use
Partner
Basic Data tab
Specify that the system does not check the standard values.
Control key
SAP
SAP
Default Values tab K1##
Internal
Capacity category
M##
Formula
DUR##
Partner
Use
Capacities tab
Scheduling tab M##
Formula
DUR##
Only
Capacity category
Costing tab
Continued on next page
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Unit 5: Resources
PLM115
Cost center
4250 1420
Activity type Duration, fixed
Internal
Only
1420 Activity type
Partner
Duration, variable FIX##
Use
Formula key Duration, fixed
SAP
SAP
VAR## Formula key
Use
Partner
Duration, variable Edit
Internal
Record category group Duration, variable
Only
Save your default resource. 2.
Creating a resource based on the default resource Create resource T-DTM1## of the resource category RE## in plant 1100. When you maintain the resource data, the system suggests values you entered for the default resource in Customizing. Continued on next page
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Lesson: Creating Resources and Further Maintenance Activities
Enter Charging vessel grp.## as the resource description on the Basic Data screen. Copy the other default values suggested on the Basic Data screen without changing them. Go through the other detail screens on: – Default values
Only
– Costing by navigating to the corresponding tab pages.
Hint: The default values will not be copied automatically from the default resource until you run through the detail screens.
Use
While doing this, pay attention to the messages in the status bar.
Internal
– Scheduling
Partner
– Capacities
3.
Creating resources with reference to existing resources In plant 1100, create the resources in the following table that are of the category RE## by copying the source T-DTM1##.
Use Internal
You only have to maintain the resource description and perhaps the task list usage on the Basic Data screen. You can then save the resource without going through further detail screens. All of the data from the screens you selected are copied from the source.
Resource
Description
T-DTR1##
Reaction vessel 1 grp ## O##
T-DTR2##
Reaction vessel 2 grp ## O##
Only
Create the following resources: Task list usage
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Partner
Select all the views that are offered for selection on the Copy from Template and choose Copy.
SAP
SAP
Save your resource.
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Unit 5: Resources
PLM115
Resource
Description
Task list usage
T-DTR3##
Reaction vessel 3 grp ## O##
T-DTA1##
Cooling tank grp ##
O##
T-DTG1##
Preliminary reaction vessel grp ##
C##
Internal
Only
How does task list usage C## restrict resource T-DTG1##? _____________________________________________ _____________________________________________
Partner
Task 5: Capacities Displaying the capacity data of a resource
Use
1.
Display the capacity data of your cooling tank T-DTA1##. Which capacity category is assigned to it? Why?
SAP
SAP
_____________________________________________ _____________________________________________ Display the capacity header data of the capacity category assigned.
Use
_____________________________________________ _____________________________________________ Creating a pooled capacity with available capacity intervals Create a pooled capacity POOL-## (personnel pool group##) of the capacity category P## in plant 1100. The data that is maintained as the default capacity for each plant and capacity category in Customizing is automatically copied. Set the Pooled capacity indicator. Set the Can be used by several operations indicator.
Continued on next page
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Internal
2.
Partner
Where was the header data of this resource capacity originally created?
PLM115
Lesson: Creating Resources and Further Maintenance Activities
The standard available capacity has an operation time of 24 hours. An average of 10 single capacities is available in the standard available capacity, and the rate of capacity utilization is 100%. Maintain the standard available capacity accordingly. Enter the detailed information for the available capacity of your pooled capacity. Define an available capacity interval for the active version 1 “Normal available capacity” according to the following information. Choose the Insert Interval icon.
Valid from:
'Today'
Valid to:
'End of this year'
Length of cycle:
1
No. of shifts:
3
Work days:
1 (overrides factory calendar)
Use
Partner
Make the following entries on the Add Available Capacity Intervals screen:
SAP
Finish
Breaks
No.
1
00:00:00
08:00:00
01:00:00
8
2
08:00:00
16:00:00
01:00:00
12
3
16:00:00
24:00:00
01:00:00
10
After defining your shifts, choose F3 'Back'. Check the available capacity interval that is valid at the moment on the 'Create Capacity: Intervals of Available Capacity' screen. Save your pooled capacity. 3.
Assigning a pooled capacity Assign your pooled capacity POOL-## of the capacity category P## to your cooling tank T-DTA1##. Check whether the capacity data has been copied correctly to the resource. Save the resource. Continued on next page
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Internal
Start
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Use
SAP
Specify the following shifts on the screen 'Create capacities: views: SNo.
Internal
Only
Choose Intervals and shifts.
Unit 5: Resources
4.
PLM115
Referencing a capacity Reference the available capacity of capacity LINE-99 of capacity category 099 to your capacity category M## in the current resource T-DTA1##. Choose Reference avail. cap. in the header data for capacity category M##. After entering the capacity on the Reference Available Capacity screen, you reference the available capacity by choosing Continue. You cannot process the available capacity within the resource.
Only
Save your resource.
Partner
Display and check the referenced capacity LINE-99.
Task 6: 1.
Use
Formulas Formulas in the Resource
SAP
______________________ ______________________
Partner
______________________
Use
SAP
On which screens is a formula key used to reference a formula defined in Customizing? Display, for example, the resource T-DTA1## again.
What is calculated with each of the formulas? _________________________________________
Internal
Internal
You also have the option of copying the available capacity and then changing it by choosing Copy.
_________________________________________ _________________________________________ Displaying and testing formulas in a resource You can display the formulas that are assigned by means of the formula keys on the resource screens. You can also test the formulas. Display the formulas defined on the Capacities, Scheduling and Costing screens for one of your resources and write down the formulas. _________________________________________ _________________________________________ Continued on next page
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2.
PLM115
Lesson: Creating Resources and Further Maintenance Activities
_________________________________________ For example, test the formula on the Scheduling screen: General operation values: (for example) Operation qty:
1,000 kg
Base quantity:
100 kg
Only Partner
Duration, fixed:
10 H
Duration,variable:
1H
Internal
Standard values (for example)
Choose Calculate... Formula constants of a resource
Use
3.
Assign the formula constant RESPOW Resource Activity to one of your resources.
SAP Use
Partner
Resource → Change / (for example) Scheduling tab /
Value
UN
RESPOW
(for example) 10000
W
Which origin must be specified for a formula parameter in Customizing so that it can be used as a resource constant? _________________________________________
Task 7: Resource selection requirements 1.
Creating a resource network Continued on next page
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Internal
Extras → Formula → Formula constants Param.
SAP
Note: Resource constants can be used as parameters in the formula for costing, capacity requirements determination, and scheduling. This may be useful for resources, for example, that have activity-dependent output.
Unit 5: Resources
PLM115
Internal
Only
Create a resource network NETZ-## according to the following graphic in plant 1100.
Figure 63: Resource Network
Description
Resource network group ##
Person responsible
R##
Assign the resources according to the network shown in the graphic above.
SAP Use
1100
Resource category:
RE##
Person responsible:
R##
Internal
On the Resource Allocation screen, select the resources and go to graphical maintenance. Create the resource network shown above in the graphic.
Partner
Plant:
SAP
Enter reasonable selection conditions, such as:
Use
Partner
Make the following entries on the Header Data screen:
Save your resource network. Displaying the network relationships of a resource Display, for example, the data on the network relationships for reaction vessel T-DTR2## in the resource master record. 3.
Classification of Resources Classify your reaction vessel in class REAC_## Reaction vessel of the class category 019 Work center class. Continued on next page
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2.
PLM115
Lesson: Creating Resources and Further Maintenance Activities
T-DTR1##
T-DTR2##
T-DTR3##
Surface
G (Glass)
P (Polyethylene)
S (Stainless steel) steel)
Rev. per min
20 - 80
20 - 40
20 - 60
Internal
Only
Assign values to the characteristics assigned for the individual reaction vessels in the following way:
Save your data.
Partner
Hint: Classification is carried out for the purpose of system-aided resource selection in the process order.
Task 8:
Use
Reporting Resources / Reporting -> < ...> Resources list
SAP
SAP
1.
Display all resources in your area of responsibility R## for plant 1100.
2.
Partner
Use
Note: Double-click one of the resources listed to display the corresponding resource data. Cost center assignment
Plant:
1100
Work center:
T-DT*##
Note: Double-click the objects listed to display data for the resources, cost centers, and activity categories. 3.
Resource capacities Display the capacities that are assigned to your resources.
Continued on next page
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Internal
Display the cost center that is assigned to your resources.
Unit 5: Resources
PLM115
Plant:
1100
Work center:
T-DT*##
Note: Double-click the capacities listed to display the corresponding capacity data. 4.
Where-used list
Only
Use
Partner
In which resources is the capacity POOL-## from plant 1100 used?
Internal
In which master recipe is, for example, the resource T-IC101 from plant 1100 used?
SAP
SAP Only
Internal
Use
Partner
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Lesson: Creating Resources and Further Maintenance Activities
Solution 10: Creating Resources and Further Maintenance Activities Task 1: Basic Customizing settings for resources
Only
1.
Basic Customizing settings for resources
Partner
a)
Customizing: SAP Customizing Implementation Guide → Production Planning for Process Industries → Master Data → Resource → (...)
Use
2.
Defining a resource category Define the resource category RE## "Processing unit group". ##'.
SAP
Specify that change documents are to be written for the resources of the category RE##.
Defining a person responsible for a resource
Use
Define the person responsible R## "Person responsible for resource group##" for plant 1100. a) 4.
(...) → General Data → Determine Person Responsible
Defining a task list usage Define the task list usages O## "Recipe & Order group##" and C## "Recipe until release, group##". Assign the task list type “Master recipe” to both task list usages.
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Internal
3.
(...) → Resource → General Data → Define Resource Category (Work Center Category)
Partner
Assign the task list usage for recipes to the resource category RE##.
SAP
Reference to the field selection and the screen sequence of the existing resource category 0008.
a)
Internal
In this exercise, you will become familiar with the most important Customizing settings for resources. Documentation is available for the individual Customizing activities, which you can display if you need help when making Customizing settings. Furthermore, you can use the F1 and F4 help for data maintenance.
Unit 5: Resources
PLM115
Restrict the task list usage ## Until order release. a) 5.
(...) → General Data → Define Task List Usage
Defining a control key Define control key K1## "Cost., Sched., Capa. Grp.##" and K2## "Cost., Sched., Capa., QM Grp.##'".
For control key K2##, also set the Inspection Characteristics Required indicator. Confirmation for phases with these control keys should be possible. 6.
(...) → Resource → Task List Data (Master Recipe)→ Define Control Keys
Defining the field selection Which field groups of the basic data screen group are defined as required entries for resource category 0008? _______________________ and _______________________ a)
(...) → Resource → General Data → Define Field Selection
SAP Use
Partner
The following are required fields: Task list use and Person Responsible
Data on capacity requirements planning Creating capacity categories Create the capacity category M## "Processing unit##" and P## "Personnel Group##". Define capacity category P## as a Labor capacity. Which function is made possible by setting the CapCatPers indicator? ______________________________________________ ______________________________________________ Continued on next page
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Only
Internal
Task 2: 1.
SAP
Position the cursor on the Basic Data screen group. Choose Influencing and enter 0008 (resource category processing unit) as the influencing value. Choose Enter.
Use
Partner
a)
Internal
Only
Set the Scheduling indicator, Capacity Requirements indicator, and Cost indicator for both control keys.
PLM115
Lesson: Creating Resources and Further Maintenance Activities
Save your entries. a)
Customizing: (...) → Resource → Capacity Requirements Planning → Define Capacity Categories Define capacity category P## as a Labor capacity. Which function is made possible by setting the CapCatPers indicator? You set this indicator to specify that persons can be assigned to this capacity category as individual capacities.
Only
Defining an area of responsibility for capacity requirements planning. Define the responsible capacity requirements planner group C## "Cap. planner grp.##".
3.
(...) → Capacity Requirements Planning → Determine Capacity Planner
Defining default capacities Define default capacities for the capacity categories M## and P## in plant 1100.
Planner group
C##
Factory calendar ID
01
Base unit of measure
H
Standard avail. capacity
Start: 00:00:00
SAP
SAP
Define the following default values for both capacity categories:
Use
No. Single cap.
1
The capacity categories are to be relevant for finite scheduling. This means that the available capacity is taken into account during capacity requirements planning. a)
(...) → Capacity Requirements Planning → Define Default Capacity
Task 3: Creating formulas for resources 1.
Defining formula parameters Define the following formula parameters: Continued on next page
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Only
Internal
100
Partner
Finish: 24:00:00 Capacity utilization
Use
Partner
a)
Internal
2.
PLM115
Param.
Origin
Key words
Dim.
Std value
Std value unit
DF##
2
Duration, fixed
TIME
H
DV##
2
Duration, variable
TIME
H
Field name
Base quantity
1
BMSCH
PHQU##
Phase qty
1
MGVRG
Hint: The parameters DF## and DV## are the standard values for a phase.
SAP
a)
Use
Defining a standard value key Define the standard value key SK## "Fixed and variable time group##" and assign the standard values DF## and DV## to it.
a) 3.
(...) → General Data → Standard Value → Define Standard Value Key
Only
Internal
Also set the Generate indicator. You use this indicator to control whether a coding command is generated for a standard value. Defining formula keys Define the following formulas:
Continued on next page
186
Partner
2.
(...) → General Data → Standard Value → Define Parameters
SAP
The parameters BAQU## and PHQU## are general operation values of the recipe or process order. The operation values are transferred to the formula parameters by way of their field names.
Use
Partner
BAQU##
Internal
Only
Unit 5: Resources
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PLM115
Lesson: Creating Resources and Further Maintenance Activities
Formula
Description
Formula definition
FIX##
Duration, fixed
DF##
VAR##
Duration, qty-dep.
DV## * PHQU## / BAQU##
DUR##
Total duration
DF## +DV## * PHQU## / BAQU##
Also allow the use of the formula for costing, capacity requirements planning, and scheduling.
Partner
a)
(...) → Capacity Requirements Planning → Formulas for Resources (Work Centers) → Define Formulas for Resources (Work Centers)
Task 4: 1.
Use
Creating a resource Defining a default resource Define a default resource for resource category RE## in plant 1100.
SAP
Internal
Resource
Person responsible
R##
Task list usage
O##
Standard value key
SK##
Partner
Use
SAP
Basic Data tab Description
Specify that the system does not check the standard values. Default Values tab
Only
Control key
K1##
Capacities tab Capacity category
M##
Formula
DUR##
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Internal
Only
Set the Generate indicator for each one.
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Unit 5: Resources
PLM115
Scheduling tab Capacity category
M##
Formula
DUR##
Costing tab 4250
Internal
Only
Cost center
1420 Activity type
Partner
Duration, fixed 1420
Use
Activity type
SAP
SAP
Duration, variable FIX##
Partner
Use
Formula key Duration, fixed
Internal
VAR## Formula key
Only
Duration, variable Edit Record category group Duration, variable
Continued on next page
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PLM115
Lesson: Creating Resources and Further Maintenance Activities
Save your default resource. a)
Customizing: (...) → Resource → General Data → Define Default Resource (Work Center) Enter the data as described in the exercise.
2.
Creating a resource based on the default resource Create resource T-DTM1## of the resource category RE## in plant 1100.
Only
Enter Charging vessel grp.## as the resource description on the Basic Data screen.
Partner
Copy the other default values suggested on the Basic Data screen without changing them.
Use
Go through the other detail screens on: – Default values – Capacities
SAP
SAP
– Scheduling – Costing by navigating to the corresponding tab pages.
Use Internal
Hint: The default values will not be copied automatically from the default resource until you run through the detail screens. Save your resource.
Only
SAP Easy Access menu: (…) → Resources → Resource → Create Enter the data as described in the exercise.
3.
Creating resources with reference to existing resources In plant 1100, create the resources in the following table that are of the category RE## by copying the source T-DTM1##. Select all the views that are offered for selection on the Copy from Template and choose Copy. Continued on next page
2005/Q2
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Partner
While doing this, pay attention to the messages in the status bar.
a)
Internal
When you maintain the resource data, the system suggests values you entered for the default resource in Customizing.
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Unit 5: Resources
PLM115
You only have to maintain the resource description and perhaps the task list usage on the Basic Data screen. You can then save the resource without going through further detail screens. All of the data from the screens you selected are copied from the source.
T-DTR1##
Reaction vessel 1 grp ## O##
Only
Task list usage
T-DTR2##
Reaction vessel 2 grp ## O##
T-DTR3##
Reaction vessel 3 grp ## O##
T-DTA1##
Cooling tank grp ##
O##
T-DTG1##
Preliminary reaction vessel grp ##
C##
Use
Description
Internal
Resource
Partner
Create the following resources:
How does task list usage C## restrict resource T-DTG1##? _____________________________________________ a)
SAP
SAP
_____________________________________________ Enter the data as described in the exercise. How does task list usage C## restrict resource T-DTG1##?
Use Internal
Task 5: Capacities
Only
1.
Displaying the capacity data of a resource Display the capacity data of your cooling tank T-DTA1##. Which capacity category is assigned to it? Why? _____________________________________________ _____________________________________________ Display the capacity header data of the capacity category assigned. Continued on next page
190
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Partner
The indicator “Usage only until release in order” was set for the task list usage in Customizing. An operation with this resource cannot be released in the process order. Before releasing it, you must replace the resource by a resource that physically exists.
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PLM115
Lesson: Creating Resources and Further Maintenance Activities
Where was the header data of this resource capacity originally created? _____________________________________________ _____________________________________________ a)
Display the capacity data of a resource in the resource: Capacities tab Which capacity category is assigned to it? Why?
Only
Choose Capacity Header Data. When you defined the default capacity for capacity category M##. 2.
Creating a pooled capacity with available capacity intervals Create a pooled capacity POOL-## (personnel pool group##) of the capacity category P## in plant 1100.
SAP
Set the Pooled capacity indicator.
Use
Enter the detailed information for the available capacity of your pooled capacity. Define an available capacity interval for the active version 1 “Normal available capacity” according to the following information. Choose Intervals and shifts. Choose the Insert Interval icon. Make the following entries on the Add Available Capacity Intervals screen:
Continued on next page
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Internal
The standard available capacity has an operation time of 24 hours. An average of 10 single capacities is available in the standard available capacity, and the rate of capacity utilization is 100%. Maintain the standard available capacity accordingly.
Partner
Set the Can be used by several operations indicator.
SAP
The data that is maintained as the default capacity for each plant and capacity category in Customizing is automatically copied.
Use
Where was the header data of this resource capacity originally created?
Display the capacity header data of the capacity category assigned.
Internal
You entered this capacity category in the default resource.
Partner
M##
Unit 5: Resources
PLM115
Valid from:
'Today'
Valid to:
'End of this year'
Length of cycle:
1
No. of shifts:
3
Work days:
1 (overrides factory calendar)
Start
Finish
Breaks
No.
1
00:00:00
08:00:00
01:00:00
8
2
08:00:00
16:00:00
01:00:00
12
3
16:00:00
24:00:00
01:00:00
10
After defining your shifts, choose F3 'Back'. Check the available capacity interval that is valid at the moment on the 'Create Capacity: Intervals of Available Capacity' screen.
SAP
a)
SAP Easy Access menu: (…) → Resources → Capacity → Create
Save the resource.
Check whether the capacity data has been copied correctly to the resource. a)
(…) → Resource → Change Capacities tab Choose Create Capacity Enter the pooled capacity you want to assign and the required capacity category. To check whether the capacity data has been copied correctly to the resource, Choose Capacity Header Data Continued on next page
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Only
Assign your pooled capacity POOL-## of the capacity category P## to your cooling tank T-DTA1##.
Partner
Use
Assigning a pooled capacity
Internal
3.
SAP
Save your pooled capacity.
Use
Partner
SNo.
Internal
Only
Specify the following shifts on the screen 'Create capacities: views:
PLM115
Lesson: Creating Resources and Further Maintenance Activities
4.
Referencing a capacity Reference the available capacity of capacity LINE-99 of capacity category 099 to your capacity category M## in the current resource T-DTA1##. Choose Reference avail. cap. in the header data for capacity category M##. After entering the capacity on the Reference Available Capacity screen, you reference the available capacity by choosing Continue. You cannot process the available capacity within the resource.
Only
Save your resource.
Partner
Display and check the referenced capacity LINE-99. a)
Reference a capacity in resource T-DTA## to capacity category M##
Use
Choose Capacity Header Data Choose Reference avail. cap. To display capacity LINE-99:
SAP
SAP
SAP Easy Access menu: (…) → Resources → Capacity → Display
Task 6:
Use
Partner
Formulas 1.
Formulas in the Resource On which screens is a formula key used to reference a formula defined in Customizing? Display, for example, the resource T-DTA1## again.
Internal
Internal
You also have the option of copying the available capacity and then changing it by choosing Copy.
______________________ ______________________
Only
______________________ What is calculated with each of the formulas? _________________________________________ _________________________________________
Continued on next page
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Unit 5: Resources
PLM115
_________________________________________ a)
On which screens is a formula key used to reference a formula defined in Customizing? Capacities Scheduling Costing
Only
Capacity requirement determination per phase Execution time calculation per phase
2.
Displaying and testing formulas in a resource You can display the formulas that are assigned by means of the formula keys on the resource screens. You can also test the formulas.
SAP
_________________________________________ _________________________________________
Use
Partner
_________________________________________ For example, test the formula on the Scheduling screen:
1,000 kg
Base quantity:
100 kg
Only
Internal
General operation values: (for example) Operation qty:
Standard values (for example) Duration, fixed:
10 H
Duration,variable:
1H
Continued on next page
194
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SAP
Display the formulas defined on the Capacities, Scheduling and Costing screens for one of your resources and write down the formulas.
Use
Partner
Activity determination of the standard values per phase to create a production cost estimate.
Internal
What is calculated with each of the formulas?
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PLM115
Lesson: Creating Resources and Further Maintenance Activities
Choose Calculate... a)
Display the formulas defined on the Capacities, Scheduling and Costing screens for one of your resources and write down the formulas. Extras → Formula → Display DUR## Duration, fixed + Duration, variable * Phase qty / Base qty FIX## Duration, fixed
Only
Internal
VAR## Duration, variable * Phase qty / Base qty For example, test the formula on the Scheduling screen Extras → Formula → Test 3.
Formula constants of a resource Assign the formula constant RESPOW Resource Activity to one of your resources.
SAP
Resource → Change /
SAP
Note: Resource constants can be used as parameters in the formula for costing, capacity requirements determination, and scheduling. This may be useful for resources, for example, that have activity-dependent output.
Use
Partner
Choose Calculate...
Partner
Use
(for example) Scheduling tab /
Param.
Value
UN
RESPOW
(for example) 10000
W
Which origin must be specified for a formula parameter in Customizing so that it can be used as a resource constant?
Continued on next page
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Only
Internal
Extras → Formula → Formula constants
Unit 5: Resources
PLM115
_________________________________________ a)
(…) → Resource → Change / (for example) Scheduling tab / Extras → Formula → Formula constants ... Which origin must be specified for a formula parameter in Customizing so that it can be used as a resource constant?
Only
Internal
F1 help for “Param." field on "Formula Constants" screen: Origin 1 “Work center constant”
Task 7: 1.
Creating a resource network Create a resource network NETZ-## according to the following graphic in plant 1100.
Use
Partner
Resource selection requirements
Partner
Use
SAP
SAP
Figure 64: Resource Network
Description
Resource network group ##
Person responsible
R##
Assign the resources according to the network shown in the graphic above. Enter reasonable selection conditions, such as:
Continued on next page
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Only
Internal
Make the following entries on the Header Data screen:
PLM115
Lesson: Creating Resources and Further Maintenance Activities
Plant:
1100
Resource category:
RE##
Person responsible:
R##
On the Resource Allocation screen, select the resources and go to graphical maintenance. Save your resource network. a)
SAP Easy Access menu: (…) → Resources → Resource Network → Create For resource allocation, choose Resource Allocation.
2.
Displaying the network relationships of a resource Display, for example, the data on the network relationships for reaction vessel T-DTR2## in the resource master record.
→ Graphic
→ Relationship Detail → Header 3.
Classification of Resources
Assign values to the characteristics assigned for the individual reaction vessels in the following way: T-DTR1##
T-DTR2##
T-DTR3##
Surface
G (Glass)
P (Polyethylene)
S (Stainless steel) steel)
Rev. per min
20 - 80
20 - 40
20 - 60
Continued on next page
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Only
Internal
Classify your reaction vessel in class REAC_## Reaction vessel of the class category 019 Work center class.
Partner
Goto → Network → Relationships
SAP
SAP
(…) → Resource → Display
Use
a)
Use
Partner
For graphical maintenance, choose the Graphic icon.
Internal
Only
Create the resource network shown above in the graphic.
Unit 5: Resources
PLM115
Save your data. Hint: Classification is carried out for the purpose of system-aided resource selection in the process order. a)
(…) → Resource → Change /
Only
1.
Internal
Task 8:
Partner
Choose Classification
Reporting Resources / Reporting -> < ...> Resources list Display all resources in your area of responsibility R## for plant 1100.
Use
Note: Double-click one of the resources listed to display the corresponding resource data.
SAP
2.
(…) →Reporting → Resources List
SAP
a)
Cost center assignment
Plant:
1100
Work center:
T-DT*##
a) 3.
(…) → Reporting → Cost Center Assignment
Only
Internal
Note: Double-click the objects listed to display data for the resources, cost centers, and activity categories.
Resource capacities Display the capacities that are assigned to your resources.
Continued on next page
198
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Partner
Use
Display the cost center that is assigned to your resources.
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PLM115
Lesson: Creating Resources and Further Maintenance Activities
Plant:
1100
Work center:
T-DT*##
Note: Double-click the capacities listed to display the corresponding capacity data. a)
Only
Where-used list In which master recipe is, for example, the resource T-IC101 from plant 1100 used?
Partner
In which resources is the capacity POOL-## from plant 1100 used? a)
(…) →Reporting → Where-Used List → Resource
Internal
4.
(…) → Reporting → Resource Capacity
(…) → Reporting → Where-Used List → Capacity
Use
SAP
SAP Only
Internal
Use
Partner
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Unit 5: Resources
PLM115
Lesson Summary You should now be able to: • Create resources • Make the basic Customizing settings for resources • Create resource networks • Classify resources for system-aided resource selection • Carry out reporting for resources
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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PLM115
Unit Summary
Unit Summary
Only
Use
Partner
Internal
You should now be able to: • Explain the structure of a resource master record. • Maintain available capacities • Create formulas and assign them in resource master records. • Create resources • Make the basic Customizing settings for resources • Create resource networks • Classify resources for system-aided resource selection • Carry out reporting for resources
SAP
SAP Only
Internal
Use
Partner
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Unit Summary
PLM115
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
202
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PLM115
Test Your Knowledge
Partner
2.
How is the term Capacity defined? According to which criterion are capacities overwritten?
3.
Which information is calculated in the process order on the basis of formulas of the assigned resources?
4.
What are the different ways for creating a resource?
Only
Internal
Partner
Use
SAP
SAP
Name the screens of a resource master record.
Use
1.
Internal
Only
Test Your Knowledge
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Test Your Knowledge
PLM115
Answers 1.
Name the screens of a resource master record. Answer:
Only Partner SAP
Answer: A capacity is the ability of a resource to perform a task with regard to time. Capacities are differentiated according to capacity categories. Which information is calculated in the process order on the basis of formulas of the assigned resources? Answer:
Use Internal
4.
Partner
• • •
Execution times Capacity requirements Production costs
What are the different ways for creating a resource?
204
Only
Answer: • • •
Manually By using a predefined default value in Customizing As a copy of another resource
© 2005 SAP AG. All rights reserved.
SAP
3.
How is the term Capacity defined? According to which criterion are capacities overwritten?
Use
2.
Basic data Default values Capacities Scheduling Costing
Internal
• • • • •
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Unit 6 Internal
Only
Production Version Unit Overview This chapter introduces you to production versions.
After completing this unit, you will be able to: Explain the definition and the interface of a production version. Create, change, and delete production versions and check their consistency Use mass processing for production versions to navigate to the master recipe and BOM
Unit Contents
Use
Only
Internal
Partner
Lesson: Production Version - Overview.......................................... 206 Lesson: Maintaining Production Versions ....................................... 209 Exercise 11: Maintaining Production Versions.............................. 215
SAP
SAP
• • •
Use
Partner
Unit Objectives
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Unit 6: Production Version
PLM115
Lesson: Production Version - Overview Lesson Overview This lesson familiarizes you with the definition and the interface of a production version.
Lesson Objectives
Only
•
Explain the definition and the interface of a production version.
Partner
Business Example You familiarize yourself with the definition and structure of a production version.
Use
Production Version
Internal
After completing this lesson, you will be able to:
SAP
SAP Only
Internal
Use
Partner
Figure 65: Production Version
206
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PLM115
Lesson: Production Version - Overview
User Interface
Use
Partner
Only
Internal SAP
SAP
Figure 66: User Interface
Maintaining Production Versions
Use
You can maintain production versions: –
Only
Internal
– –
In mass processing (recommended; required for approval procedures using change orders) In the master recipe In the material master
Partner
•
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Unit 6: Production Version
PLM115
Lesson Summary You should now be able to: • Explain the definition and the interface of a production version.
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
208
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PLM115
Lesson: Maintaining Production Versions
Lesson: Maintaining Production Versions Lesson Overview This lesson familiarizes you with the maintenance activities for production versions.
Lesson Objectives
Only
Business Example
Create, change, and delete production versions and check their consistency Use mass processing for production versions to navigate to the master recipe and BOM
Internal
• •
Partner
After completing this lesson, you will be able to:
In every production version, you define the master recipe and BOM to be used for the corresponding production process.
Use
Mass Processing: Overview
SAP
SAP
You create the production versions for the materials to be produced in your company.
Only
Internal
Use
Partner
Figure 67: Mass Processing: Overview
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Unit 6: Production Version
PLM115
You can select a worklist of production versions to be processed in the maintenance transaction Production Version: Mass Processing. The worklist allows you to carry out both mass processing and individual processing of production versions.
Mass Processing: Information and Functions
Use
Partner
Only
Internal Only
Internal
From the worklist, you can perform all maintenance activities, such as creating, copying, changing, displaying, and deleting production versions.
Partner
Use
SAP
SAP
Figure 68: Mass Processing: Information and Functions
210
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PLM115
Lesson: Maintaining Production Versions
Recommended Recipe Processing
Partner
From mass processing of production versions, you can navigate to the corresponding master recipe and create or edit the recipe or alternative BOM there. From the production version, you can thus access all production-related master data.
Use
SAP
Only
Internal
Figure 69: Recommended Recipe Processing
Use Internal
A production version is considered approved when it meets the following requirements (see also the unit Engineering Change Management and Recipe Approval): • • •
2005/Q2
The master recipe assigned to the production version has a change rule that requires an engineering change order with or without a change type. The production version has been assigned a change number that complies with this change rule. The relevant engineering change order has been released. This means you can no longer use it for changes.
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Only
When you create process orders that require approval, the system uses the number of the engineering change order to check whether the production version has been approved.
Partner
In this way, an approval procedure must be applied consistently to all objects belonging together by way of the assignment of an engineering change order.
SAP
You can assign a change number or engineering change order to a production version in mass processing only (and not in the material master record or master recipe). This is then also valid for recipe and BOM maintenance.
Unit 6: Production Version
PLM115
Production versions whose change rule requires an engineering change order cannot be processed until a valid engineering change order was assigned. Note: In the standard system, you can therefore not edit production versions whose change rule requires an engineering change order in the material master record.
Internal
Only
Note: Unlike recipe editing with a change master record or engineering change order, you do not create a new change status for the production version. You only assign the change number to it in the worklist of mass processing. You may need to adjust the validity period of the production version manually.
SAP
SAP
Use
Partner
Production Version Consistency
Figure 70: Production Version Consistency
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•
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The lot-size range of the production version must be in the lot-size range of the assigned recipe as well as that of the assigned alternative BOM. This applies to all change statuses of the recipe and alternative BOM that are in the validity period of the production version. The assigned recipe and alternative BOM must exist during the whole validity period of the production version. The deletion flag must not be set for them.
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Internal
•
Partner
In order for a production version to be consistent, it must fulfill the following requirements:
PLM115
Lesson: Maintaining Production Versions
Consistency Check
Use Internal
If the data is not consistent, an error or warning message is given in the inspection result. After the check, the date of the last check and the check status are updated.
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The recipe, task list, or BOM are assigned one of the following statuses in the production version: Last check ok (green light) Not yet checked (yellow light) Last check with error (red light)
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You can check whether the data of a production version is consistent with the data of the master recipe and the data of the alternative BOM assigned to it. You can then be sure that a valid recipe or valid BOM actually exists within the whole validity period of the production version.
SAP
SAP
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Internal
Figure 71: Consistency Check
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Unit 6: Production Version
PLM115
Locking a Production Version
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Internal
SAP
You can lock production versions (for any usage).
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Internal
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If the check result is negative, a production version is not automatically locked. If required, you can set the lock indicator manually.
SAP
Figure 72: Locking a Production Version
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PLM115
Lesson: Maintaining Production Versions
Exercise 11: Maintaining Production Versions Exercise Objectives
Only
Business Example
Partner
You create the production versions for the materials to be produced in your company. In every production version, you define the master recipe and BOM to be used for the corresponding production process.
Use
Task 1: Creating a production version
Use
SAP
Detergent
From lot size
1000
To lot size
20000
Valid from
Today
Valid to
No entry = maximum validity date
Detailed planning Master recipe
Group
T-DET1##
Group counter
1
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Task list type
BOM Alternative BOM
1
BOM usage
1 Production Continued on next page
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Production version text
Internal
Create production version 0001 for material T-FD1## in plant 1100 according to the following specifications:
SAP
1.
Internal
After completing this exercise, you will be able to: • Create, change, and delete production versions and check their consistency • Use mass processing for production versions to navigate to the master recipe and BOM
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Unit 6: Production Version
2.
PLM115
Which warnings appear after detail maintenance for the production version? ______________________________________________________ ______________________________________________________ ______________________________________________________
3.
Use the Application help to find out more about the symbol that appears in the Processing status column. What does this symbol mean?
Only
Internal
______________________________________________________ Save your production version.
Task 2:
Partner
Copying and changing production versions Create production versions as copies of existing production versions.
Use
Then change the copies.
Use
Copy production version 0001 to production version 0002 and change the number of the alternative BOM from 1 to 2.
2.
Copy production version 0002 to production version 0003 and change the Valid-from date from today to today + 2 months on the detail screen. Also change the number of the alternative BOM from 2 to 3.
3.
Copy production version 0001 to production version 0004 and change the lot-size range 1000 - 20000 to 20000 - 30000. Also change the group counter from 1 to 2.
Task 3: Consistency check for production version / processing status 1.
Perform a consistency check for one or more production versions of material T-FD1##.
2.
Which messages appear in the consistency log? ______________________________________________________ ______________________________________________________
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Internal
Then save the production versions.
Partner
1.
SAP
SAP
You can, for example, proceed as described in the following exercise:
PLM115
Lesson: Maintaining Production Versions
3.
How do you recognize that a consistency check has been performed for these production versions? ______________________________________________________ ______________________________________________________
4.
What is displayed in the Processing status column? ______________________________________________________
Only
5.
Internal
Save the production versions. How does the processing status change after you saved? ______________________________________________________
Production version in the material master 1.
The production versions that you created in the previous exercises are defined in the master data record of material T-FD1##. Display the production versions in the material master (MRP 4 view).
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Task 4:
SAP
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Unit 6: Production Version
PLM115
Solution 11: Maintaining Production Versions Task 1: Creating a production version Create production version 0001 for material T-FD1## in plant 1100 according to the following specifications:
Internal
From lot size
1000
To lot size
20000 Today
Valid to
No entry = maximum validity date
Group counter Alternative BOM
1
BOM usage
1 Production
Detailed planning Master recipe
Group
T-DET1## 1
SAP
Task list type
BOM
Internal
a)
SAP Standard Menu → Logistics → Production - Process → Master Data → Production Versions Enter plant 1100 and material T-FD1## as your selection conditions.
Only
Choose the Create production version icon. The Maintenance Production Version: Detail Screen appears. Enter the data as described in the exercise. 2.
Which warnings appear after detail maintenance for the production version? ______________________________________________________ ______________________________________________________
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Partner
Valid from
Use
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Detergent
SAP
Production version text
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1.
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PLM115
Lesson: Maintaining Production Versions
______________________________________________________ a)
The following warnings appear: "Valid to" date is automatically set to the maximum No task list available. No BOM available.
Use the Application help to find out more about the symbol that appears in the Processing status column. What does this symbol mean? ______________________________________________________ Save your production version.
Partner
a)
Help → Application help The symbol means the following:
Use
stands for Production version is new
Internal
Only
3.
Task 2:
SAP
SAP
Copying and changing production versions Create production versions as copies of existing production versions. Then change the copies.
Use
1.
Copy production version 0001 to production version 0002 and change the number of the alternative BOM from 1 to 2. a)
Internal
Partner
You can, for example, proceed as described in the following exercise:
Copy production version 0001 to production version 0002: Select production version 0001. Choose the Copy production version icon.
Only
Enter number 0002 in the Copy / Prod. Version field. Choose Enter. Then enter alternative BOM 2 for production version 0002 in mass processing or on the detail screen. Choose Enter to confirm warnings.
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Unit 6: Production Version
2.
PLM115
Copy production version 0002 to production version 0003 and change the Valid-from date from today to today + 2 months on the detail screen. Also change the number of the alternative BOM from 2 to 3. a)
Copy production version 0002 to production version 0003. Select production version 0002. Choose the Copy production version icon.
Only
3.
Copy production version 0001 to production version 0004 and change the lot-size range 1000 - 20000 to 20000 - 30000. Also change the group counter from 1 to 2. Then save the production versions. a)
Copy production version 0001 to production version 0004.
SAP
Change the lot-size range and the group counter as described in the exercise.
Task 3: Consistency check for production version / processing status Perform a consistency check for one or more production versions of material T-FD1##. a)
Select one or more production versions.
Only
Internal
1.
Choose the Consistency check icon. The consistency log for the production versions appears. 2.
Which messages appear in the consistency log? ______________________________________________________
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220
Partner
Use
Choose Enter to confirm warnings.
SAP
Copy production version 0001 as described above.
Use
Choose Enter to confirm warnings.
Change the Valid-from date and the Alternative BOM as described in the exercise.
Internal
Choose Enter.
Partner
Enter number 0003 in the Copy / Prod. Version field.
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PLM115
Lesson: Maintaining Production Versions
______________________________________________________ a)
The consistency log contains the following error messages: Task list is not available. BOM is not available. Choose Back.
How do you recognize that a consistency check has been performed for these production versions? ______________________________________________________ ______________________________________________________
4.
The current date was entered in the Check date column. In addition, the test status Check with errors was set (red traffic light).
What is displayed in the Processing status column?
Use
Partner
a)
______________________________________________________ Save the production versions.
SAP
The Processing status column shows that the production version data was changed. Note: The production version is therefore locked for other users until you save it.
Partner
Use
Save the production versions. How does the processing status change after you saved?
Internal
______________________________________________________ a)
SAP
a)
5.
Internal
Only
3.
The following changes when you save: The symbol in the Processing status column disappears.
Only
Note: The production version is now unlocked again.
Task 4: Production version in the material master 1.
The production versions that you created in the previous exercises are defined in the master data record of material T-FD1##. Continued on next page
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Unit 6: Production Version
PLM115
Display the production versions in the material master (MRP 4 view). a)
SAP Easy Access menu: Logistics → Production -Process → Master Data → Material Master → Material → Display → Display Current Choose MRP4 view. Choose ProdVersions.
Choose Details to navigate to the Production Version Details screen.
Use
Partner
Hint: If you enter the material master in the change mode, you can also create, check, and delete production versions in this way, provided the production versions do not belong to approved recipes.
Internal
Only
On the Production Version Overview screen, the production versions just created are listed.
SAP
SAP Only
Internal
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Lesson: Maintaining Production Versions
Lesson Summary You should now be able to: • Create, change, and delete production versions and check their consistency • Use mass processing for production versions to navigate to the master recipe and BOM
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SAP Only
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Unit Summary
PLM115
Unit Summary You should now be able to: • Explain the definition and the interface of a production version. • Create, change, and delete production versions and check their consistency • Use mass processing for production versions to navigate to the master recipe and BOM
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Test Your Knowledge
What is does a production version determine?
2.
Name some of the functions available in the mass processing for maintaining production versions.
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1.
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Test Your Knowledge
SAP
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Test Your Knowledge
PLM115
Answers 1.
What is does a production version determine? Answer: A production version determines which master recipe is used together with which material BOM to produce a material. Name some of the functions available in the mass processing for maintaining production versions. Answer:
SAP
SAP
Partner
Change (detail maintenance) Create Delete Copy Consistency check Assign change number Navigation in master recipe (create, change)
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• • • • • • •
Internal
Only
2.
Only
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Unit 7 Unit Overview
Unit Objectives After completing this unit, you will be able to:
SAP
Describe the basic structure of a master recipe. Create and maintain the header, operation, and phase data of a master recipe Carry out scheduling in the master recipe
Unit Contents
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Only
Internal
Partner
Lesson: Master Recipes: Overview .............................................. 228 Exercise 12: Master Recipes: Overview .................................... 233 Lesson: Creating Header and Operation Data.................................. 238 Exercise 13: Creating Header and Operation Data ........................ 251
SAP
• • •
Use
Partner
This chapter introduces you to the maintenance of the header, transaction and phase data of a master recipe.
Internal
Only
Master Recipes (I)
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Unit 7: Master Recipes (I)
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Lesson: Master Recipes: Overview Lesson Overview This lesson provides an overview of the elements, structure and functions of a master recipe.
Lesson Objectives
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•
Describe the basic structure of a master recipe.
Partner
Business Example To map the production process onto the system in more detail, you must create the relevant master recipes and BOMs.
Internal
After completing this lesson, you will be able to:
Use
First of all, find out the basic structure of a master recipe.
Elements of a Master Recipe
SAP
SAP Only
Internal
Use
Partner
Figure 73: Elements of a Master Recipe
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PLM115
Lesson: Master Recipes: Overview
A master recipe defines the following data that is required for the production of materials without relating to a particular order: processing steps, resources, material components, data for quality inspection during production, and control information for the process control level. The master recipe is the basis for the creation of process orders. A process order describes an actual production process and contains, for example, production dates and quantities to be produced.
Only Partner
Functions of a Master Recipe
Internal
A control recipe contains all the information necessary for the execution of a process order by a certain process control system or process operator. Control recipes are generated from the process instructions in a process order and transferred to the corresponding destination in process control. Process instructions are defined in the master recipe on which the process order is based.
Use
SAP
SAP Only
Internal
Use
Partner
Figure 74: Functions of a Master Recipe
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Unit 7: Master Recipes (I)
PLM115
Recipe and Recipe Group
Partner
Only
Internal
Figure 75: Recipe and Recipe Group
SAP
Master recipes that belong to the same recipe group can be assigned to different plants.
SAP
Thus, a master recipe is identified by its recipe group and a recipe counter.
Use
You always create a master recipe in a recipe group. You can create several recipes in a recipe group, for example, for organizational reasons.
Only
Internal
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Lesson: Master Recipes: Overview
Structure of the Master Recipe
Use
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Only
Internal
SAP
SAP
Figure 76: Structure of the Master Recipe
Use
In material quantity calculation, you define formulas to calculate the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the ingredients, yield ratios of the products and remaining materials as well as specific material attributes (for example, active ingredient).
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Only
The material list is made up of components representing the materials entering and leaving the production process, as well as temporarily existing materials and their planned quantities. It also defines the assignment of these material components to the phases of the recipe according to their planned appearance in the process.
The processing sequence of the phases is defined in relationships.
Partner
Exactly one resource is assigned to an operation. This assignment of the resource is also valid for all phases that belong to the operation.
Internal
The recipe header contains data that is valid for the whole recipe. Operations describe the different steps required during the production process. For a more detailed description of these steps, phases are assigned to the operations.
Unit 7: Master Recipes (I)
PLM115
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Internal
SAP
SAP Only
Internal
Use
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PLM115
Lesson: Master Recipes: Overview
Exercise 12: Master Recipes: Overview Exercise Objectives After completing this exercise, you will be able to: • Describe the basic structure of a master recipe
To map the production process onto the system in more detail, you must create the relevant master recipes and BOMs. First of all, find out about the basic structure of a master recipe.
Elements and structure of a master recipe 1.
Go to mass processing for production versions. Select the production version(s) for plant 1100 and master recipe group T-ICE##.
SAP
2.
Operation overview Familiarize yourself with the operations, phases, and resources assigned.
Use
Relationships Display the relationships defined between the phases in the operation graphic.
Internal
4.
Recipe header data Display the recipe header data.
Partner
3.
SAP
For production version 0001 of material T-FI1##, get an overview of the data in the corresponding master recipe.
Use
Partner
Task:
Internal
Only
Business Example
Navigate to the material assignments.
Only
Which materials are assigned to the recipe as products? ________________________ ________________________ ________________________ 5.
Material list
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Unit 7: Master Recipes (I)
PLM115
Familiarize yourself with the material components that are assigned to the recipe for product T-FI1##. Which material components are assigned? In which quantities are the material components required? To which operations or phases are the material components assigned? Material
Quantity
Operation / Phase
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Only
Internal
(5 examples are sufficient)
Use
SAP
SAP Only
Internal
Use
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Lesson: Master Recipes: Overview
Solution 12: Master Recipes: Overview Task: Elements and structure of a master recipe 1.
Go to mass processing for production versions. Select the production version(s) for plant 1100 and master recipe group T-ICE##.
Only
a)
(…) → Production – Process → Master Data → Production Versions
Partner
Plant: 1100 Task list type: 2
Internal
For production version 0001 of material T-FI1##, get an overview of the data in the corresponding master recipe.
Task list group: T-ICE##
Use
Choose Enter. Select production version 0001 of material T-FI1##.
SAP
SAP
Choose Recipe On the Parameters for Recipe Maintenance dialog box: Choose the Display Recipe icon
Use
Operation overview Familiarize yourself with the operations, phases, and resources assigned. a)
Internal
3.
Operations tab
Relationships Display the relationships defined between the phases in the operation graphic. Operations tab
Only
a)
Operation Graphic icon 4.
Recipe header data Display the recipe header data. Navigate to the material assignments. Which materials are assigned to the recipe as products? ________________________ Continued on next page
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2.
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Unit 7: Master Recipes (I)
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________________________ ________________________ a)
Choose the Recipe Header tab Which materials are assigned to the recipe as products? Choose Material Assignments. T-FI1##
Only
T-FI3## 5.
Material list
Partner
Familiarize yourself with the material components that are assigned to the recipe for product T-FI1##.
Use
Which material components are assigned? In which quantities are the material components required? To which operations or phases are the material components assigned?
SAP
Operation / Phase
Partner
Use
Quantity
First navigate to the Recipes tab. Then select the recipe and choose the Materials icon.
236
Material
Quantity
Operation / Phase
T-RI0##
0.1 KG
1010
T-RI1##
0.12 KG
1010
T-RI2##
0.16 KG
1010
T-RI3##
0.02 KG
1010
T-RI4##
0.02 KG
1010
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Internal
(5 examples are sufficient) a)
SAP
Material
Internal
T-FI2##
PLM115
Lesson: Master Recipes: Overview
Lesson Summary You should now be able to: • Describe the basic structure of a master recipe.
Use
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Internal
SAP
SAP Only
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Unit 7: Master Recipes (I)
PLM115
Lesson: Creating Header and Operation Data Lesson Overview This chapter introduces you to the maintenance of the header and operation data of a master recipe.
Only
Create and maintain the header, operation, and phase data of a master recipe Carry out scheduling in the master recipe
You have created production versions for the materials to be produced in your company. In production versions, you have defined the master recipe and BOM to be used for each product.
SAP
First, you create the header, operation, and phase data for your recipes.
SAP
To map the production process onto the system in more detail, you must now create the relevant master recipes and BOMs.
Use
Business Example
• •
Internal
After completing this lesson, you will be able to:
Partner
Lesson Objectives
Only
Internal
Use
Partner
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Lesson: Creating Header and Operation Data
Creating Master Recipes and BOMs
Use
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Only
Internal
Figure 77: Creating Master Recipes and BOMs
SAP
•
– The operation – The relationship – Process defaul maintenance – The relationship graphic – Changeability Quality assurance default values
When creating a master recipe, you must enter a profile defined in Customizing. You find the default values defined in the profile in the Extras menu of the master recipe.
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Internal
Use
Default values for the master recipe:
Partner
•
SAP
Profile
Unit 7: Master Recipes (I)
PLM115
Recipe header data
Only
Data that is valid for the whole recipe is maintained at the recipe header level.
SAP Use
The materials to be produced using the recipe are assigned to the recipe at the header level. To give more information, you can create a long text for the recipe header. On the QM Data recipe header detail screen, you can define the type of in-process inspection. Administrative data provides information on the validity of the recipe as far as time is concerned, as well as on the persons who have created or changed the recipe. It also tells you whether a change was made using a change number.
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Internal
By defining a change rule, you can specify how the recipe can be changed (without rule, with change number, with engineering change order).
Partner
With the charge quantity range, you specify a value range that is allowed for the production quantity and for which the master recipe may be used as the reference for a process order in production.
SAP
The status provides information on the processing status of a recipe (for example, creation phase, released for order, released for costing) and controls which business operations are allowed or not allowed. The usage describes the purpose for which the recipe can be used (for example, production, construction, plant maintenance). The planner group specifies a group of people who are responsible for the maintenance of the recipe.
Use
Partner
Recipe group, recipe counter, recipe description, plant Resource network Status Usage Planner group Charge quantity range Change rule Material-recipe assignment QM data is Long text Administrative data
Internal
• • • • • • • • • • •
PLM115
Lesson: Creating Header and Operation Data
Maintaining Operations and Phases
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Internal
SAP
(*) If the recipe intends the process default maintenance using XSteps, then control recipe recipients and process defaults cannot be maintained for the phases.
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Only
Internal
Partner
The maintenance is then carried out using the XSteps editor of the recipe.
SAP
Figure 78: Maintaining Operations and Phases
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Operation Overview
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Figure 79: Operation Overview
SAP Use
• •
Whether scheduling is to be carried out for the phase Whether capacity load records are to be written for the phase Whether the phase is costed Whether a goods receipt is to be posted automatically for the process order when a confirmation is received Whether time tickets are to be printed for the operation or phase Whether inspection characteristics have to be maintained for the operation or phase
Note: Scheduling, determination of capacity requirements, and costing take place at phase level. The dates and capacity requirements for operations are derived from the corresponding phases.
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• • • •
Partner
Control keys are defined in Customizing. You can set a number of different indicators specifying, for instance:
SAP
You must enter a control key for each operation and phase. The control key determines how an operation or phase is to be processed in functions such as process orders, costing, and capacity requirements planning.
PLM115
Lesson: Creating Header and Operation Data
Standard and Default Values from the Resource
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Only
Internal
Figure 80: Standard and Default Values from the Resource
SAP Use
Only
Internal
Using the standard text key, you can assign a standard text created previously to the description of an operation or phase.
Partner
The default values are then either copied into the operation or phase, giving you the possibility to later change them, or they are referenced into the operation or phase, thus making further changes impossible. In the latter case, a reference indicator is set for the relevant default value in the resource.
SAP
You can use a rule for maintenance to specify whether a standard value for a phase may be, should be, or has to be entered. In the resource, you can also maintain default values for the units of measure of the standard values.
Use
When you assign a resource to an operation, you also assign the standard and default values maintained in the resource to the phases of the operation.
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Unit 7: Master Recipes (I)
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Relationships
SAP
Relationships Between Master Recipes
SAP
The time-based sequence of phases is determined by relationships. Relationships link the start and finish points of phases. This enables you, for instance, to synchronize phases belonging to different operations.
Use
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Internal
Figure 81: Relationships
Only
Internal
Use
Partner
Figure 82: Relationships Between Master Recipes
Phases from different recipes can be linked using relationships.
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PLM115
Lesson: Creating Header and Operation Data
Assigning Secondary Resources
Use
Partner
Only
Internal
Figure 83: Assigning Secondary Resources
SAP Use
You must assign a control key to each secondary resource. The same business transactions can be carried out for secondary resources as for operations and phases. Secondary resources can, for example, be included in scheduling, capacity requirements planning, and costing.
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Internal
If required, you can assign additional secondary resources to operations and phases. This assignment can be carried out with a flexible start and finish time, relative to the start or finish of the operation or phase.
Partner
The primary resource is also assigned to all phases subordinate to the operation in the hierarchy.
SAP
Exactly one (primary) resource is assigned to an operation. The primary resource is that part of a line or processing unit at which the operation is carried out. It is committed for the entire duration of the operation.
Unit 7: Master Recipes (I)
PLM115
Scheduling in the Master Recipe
SAP Use
The scheduling result can be used to update the in-house production time in the material master record of the material assigned via the production version. Depending on the scheduling type, the float before production is either added to the basic start date, or the float after production is subtracted from the basic finish date. In this way you can determine the planned start and finish dates of production (scheduled start date, scheduled finish date). The float before production and float after production are time buffers enabling you to react to disturbances in the manufacturing process. You can assign them to the material in the MRP view of the material master record using the scheduling margin key.
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Only
The scheduling result can either be displayed in a table or graphically in a Gantt chart. Due to the relationships, phase dates can have certain time buffers. Therefore, the earliest and latest start and finish dates are determined in scheduling.
Partner
Starting from the basic start or basic finish dates, scheduling is carried out either as forward or backward scheduling. You can enter a planned lot size if the phase duration depends on the quantity to be processed.
Internal
To be able to carry out scheduling, you must maintain default values for phases as well as relationships between phases.
SAP
Scheduling a master recipe enables a time-based simulation of the manufacturing process in the planning phase. During scheduling, the start and finish times of phases are determined. Scheduling takes place at phase level only. The operation dates are derived from the phase dates.
Use
Partner
Only
Internal
Figure 84: Scheduling in the Master Recipe
PLM115
Lesson: Creating Header and Operation Data
Phase Duration
Use
Partner
Only
Internal
To calculate the phase duration, you must specify a capacity category in the resource as the scheduling basis and define a formula in the resource.
Use
When calculating the phase dates, the available capacity of the scheduling basis including breaks is taken into account.
Only
Internal
Scheduling takes place via the phases. The operation dates are derived from the phase dates.
Partner
The phase duration is determined on the basis of the standard values and additional formula parameters.
SAP
SAP
Figure 85: Phase Duration
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Unit 7: Master Recipes (I)
PLM115
Classification of Operations and Resources
Use
Partner
Only
Internal
Using classes of class type 019 work center type, you can classify resources as well as operations contained in master recipes.
Use
Only
Internal
The characteristic values of classified operations represent the selection conditions for system-aided resource selection in the process order.
Partner
You can thus use the characteristics of a class of class type 019 in two ways: first, you can store specific resource attributes and second, you can define selection conditions a resource must meet if it is to be used in an operation of a master recipe.
SAP
SAP
Figure 86: Classification of Operations and Resources
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PLM115
Lesson: Creating Header and Operation Data
Checking the Recipe / Consistency Log
If you want to check whether the data for your recipe is complete and consistent, choose Check Recipe Group.
SAP
SAP
After the recipe is checked, warnings, information, and errors are collected for the recipe check in a consistency log.
Use
Partner
Only
Internal
Figure 87: Checking the Recipe / Consistency Log
Only
Internal
Use
Partner
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Unit 7: Master Recipes (I)
PLM115
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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PLM115
Lesson: Creating Header and Operation Data
Exercise 13: Creating Header and Operation Data Exercise Objectives
Only
Business Example
To map the production process onto the system in more detail, you must now create the relevant master recipes and BOMs.
SAP
SAP
First, you create the header, operation, and phase data for your recipes.
Task 1: Creating a master recipe
Use
Go to mass processing for production versions. Select the production version(s) for plant 1100 and material T-FD1##.
Internal
Create a master recipe for production version 0001 based on the following information: Data on recipe maintenance access: Valid-from date of ProdVers
Profile:
0001
Only
2.
Key date:
Data for recipe header a) The Create Master Recipe: Recipe screen appears. Enter the following data on the Recipe header tab page:
Continued on next page
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Partner
1.
Use
Partner
You have created production versions for the materials to be produced in your company. In production versions, you have defined the master recipe and BOM to be used for each product.
Internal
After completing this exercise, you will be able to: • Create and maintain the header, operation, and phase data of a master recipe • Carry out scheduling in the master recipe • Classify operations for system-aided resource selection
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Recipe description:
Recipe for detergent production, grp ##
Plant:
1100
Status:
4 “Released general”
Use:
1 "Production"
Planner group:
001 “Planner group 001”
Resource network:
NETZ-##
Charge quantity range:
1000 – 20000 L
Internal
Only
Unit 7: Master Recipes (I)
b) Header text Choose the Header Text icon. Long text: Recipe for detergent production, grp ## ##, exothermic reaction. c) Administrative data Display the administrative data.
SAP
SAP
Administrative Data tab 3.
Use
Partner
Create a long text that describes the recipe in more detail.
Operations and phases a) Creating operations and phases and assigning resources
Use
Op
Ph
SOp
CRD
100
Resource
Description
T-DTM1## CHARGING
110
x
100
EN
Charge
120
x
100
EN
Mix
130
x
100
EN
Add water
140
x
100
EN
Discharge
Continued on next page
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Internal
Operations tab
Partner
Create operations and phases for your recipe 1 of the recipe group T-DET1## based on the data in the following table. Assign the resources shown on the table.
PLM115
Lesson: Creating Header and Operation Data
Op
Ph
SOp
CRD
T-DTG1## REACTION
210
x
200
EN
Charge
220
x
200
EN
Add Butanol and NaOH
230
x
200
EN
Discharge
300
T-DTA1## COOLING
310
x
300
EN
Charge
320
x
300
EN
Cool
330
x
300
EN
Discharge
Save your master recipe.
SAP
Use the input help (F4) to display detailed information about the control key K1##.
SAP
b) Control key
Use
Partner
Description
Internal
Only
200
Resource
____________________ ____________________
Internal
____________________ Based on the indicators that have been set, what happens to a phase marked with this control key in the process order?
Only
______________________________________ ______________________________________ ______________________________________ Use field help (F1) to display information about the functions of the different indicators. c) Text (for operation / for phase) Continued on next page
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Partner
Use
Which indicators are set?
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Unit 7: Master Recipes (I)
PLM115
Create the following text for operation 200. Choose the Text icon. Text: Reaction Resource selection conditions have been defined for the operation so that a suitable reaction vessel can be selected.
Only
Display the administrative data for an operation or a phase. e) Maintaining standard values
Act. type
(2nd std. value)
1420
10 min
1420
Use
Phase
Duration, fixed
Act. type
130
10 min
1420
140
10 min
1420
210
10 min
1420
220 230
10 min
1420
310
10 min
1420
20 min
1420
SAP
(1st std. value) 110 120
30 min
1420
1420
330 4.
Only
5h
1420
Partner
320
30 min
SAP
Duration, variable
Internal
The quantity-dependent durations should each refer to a base quantity of 1000 L.
a) Assigning a secondary resource Add the secondary resource T-DTT1## "Transport vehicle" for phase 330.
Continued on next page
254
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Use
Partner
Maintain the standard values for the phases of your recipe according to the information in the following table.
Internal
d) Administration data
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PLM115
Lesson: Creating Header and Operation Data
Sec.res.
Resource
Plant
Description
0001
T-DTT1##
1100
Discharge into transport unit
b) Text (for secondary resource) Enter the following text for your secondary resource.
Only
It cannot be detached until 10
Internal
Discharge into transport unit
Partner
Text: 15 minutes before charging begins the transport vehicle must be connected. minutes after charging is
Use
finished. c) Standard value and earliest and latest dates
SAP Use
45 min.
Offset to start:
15 min.
Offset to finish:
10 min.
Partner
Duration:
d) Administration data
Internal
SAP
Define the standard value and the earliest and latest dates of your secondary resource according to the following information.
Display the administrative data for your secondary resource. Save your recipe.
Only
5.
Relationships a) Graphical maintenance / maintenance by means of the Generate Relationships function Create the relationships between the phases of your recipe as shown in the following graphic. Use graphical maintenance and/or the Generate Relationships function.
Continued on next page
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Unit 7: Master Recipes (I)
PLM115
Figure 88: Graphical Maintenance
b) Maintenance on the phase detail screen 320------330
Successor
Phase
X
330
Relationship type
Rcp. grp
Recipe
T-DET1##
1
Use
Partner
in the detail screen for phase 320.
FS
SAP
SAP
Finish - start
Display the detail information for this relationship.
Use
Partner
Choose the Detail icon for the relationship you created. Display the administrative data for this relationship. Administrative Data tab
Internal
c) Displaying information in graphical maintenance Go back to the graphic display of the relationships.
Only
Double-click a phase. Which phase detail screen appears? ____________________ Double-click a line connecting two phases. Which relationship detail screen appears? ____________________ Save your recipe. Continued on next page
256
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Internal
Only
Maintain the last relationship
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PLM115
Lesson: Creating Header and Operation Data
Task 2: Classifying operations 1.
Classify the operation 200 in the class REAC_## "Reaction vessel".
Surface coating
P
Revolutions per Min.
30
Save your master recipe.
Partner
Hint: The classification of the operation defines the selection conditions for a system-aided resource selection in the process order.
Use
Task 3: Scheduling Suggestion: Do the following exercise for different charge quantities.
SAP
Scheduling overview
SAP
1.
Simulate order scheduling in your master recipe. On the operation overview,
Partner
Use
Schedule Recipe icon Display the result in the scheduling overview.
Internal
2.
Internal
Only
Assign the following values to the characteristics:
Gantt chart Display the scheduling results in the Gantt chart. Choose the Gantt Chart icon.
Only
Select a suitable time unit.
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Unit 7: Master Recipes (I)
PLM115
Solution 13: Creating Header and Operation Data Task 1: Creating a master recipe Go to mass processing for production versions. Select the production version(s) for plant 1100 and material T-FD1##. Create a master recipe for production version 0001 based on the following information:
Key date:
Valid-from date of ProdVers
Profile:
0001
a)
Use
Partner
Data on recipe maintenance access:
(...) → Production versions Select the production version for material T-FD1##
SAP
SAP
Select production version 0001 of material T-FD1##. Choose Recipes. Parameters for Recipe Maintenance dialog box:
Use
Data for recipe header
Recipe description:
Recipe for detergent production, grp ##
Plant:
1100
Status:
4 “Released general”
Use:
1 "Production"
Continued on next page
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Only
Internal
a) The Create Master Recipe: Recipe screen appears. Enter the following data on the Recipe header tab page:
Partner
Edit Recipe icon 2.
Internal
Only
1.
PLM115
Lesson: Creating Header and Operation Data
Planner group:
001 “Planner group 001”
Resource network:
NETZ-##
Charge quantity range:
1000 – 20000 L
b) Header text Create a long text that describes the recipe in more detail.
Only
Long text: Recipe for detergent production, grp ## ##, exothermic reaction. c) Administrative data
Partner
Display the administrative data. Administrative Data tab a)
Maintain the data as described in the exercise.
Use
3.
Operations and phases a) Creating operations and phases and assigning resources
SAP
Operations tab
Use
SOp
CRD
Description
T-DTM1## CHARGING
110
x
100
EN
Charge
120
x
100
EN
Mix
130
x
100
EN
Add water
140
x
100
EN
Discharge
200 210
T-DTG1## REACTION x
200
EN
Charge
Continued on next page
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Only
Internal
100
Resource
Partner
Ph
SAP
Create operations and phases for your recipe 1 of the recipe group T-DET1## based on the data in the following table. Assign the resources shown on the table.
Op
Internal
Choose the Header Text icon.
Unit 7: Master Recipes (I)
PLM115
Op
Ph
SOp
CRD
220
x
200
EN
Add Butanol and NaOH
230
x
200
EN
Discharge T-DTA1## COOLING
310
x
300
EN
Charge
320
x
300
EN
Cool
330
x
300
EN
Discharge
Save your master recipe. b) Control key Use the input help (F4) to display detailed information about the control key K1##.
SAP
SAP
Which indicators are set? ____________________ ____________________
Use
Based on the indicators that have been set, what happens to a phase marked with this control key in the process order? ______________________________________ ______________________________________ Use field help (F1) to display information about the functions of the different indicators. c) Text (for operation / for phase) Create the following text for operation 200. Choose the Text icon. Text: Reaction Continued on next page
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Only
Internal
______________________________________
Partner
____________________
260
Use
Partner
Description
Internal
Only
300
Resource
PLM115
Lesson: Creating Header and Operation Data
Resource selection conditions have been defined for the operation so that a suitable reaction vessel can be selected. d) Administration data Display the administrative data for an operation or a phase. e) Maintaining standard values
Only
The quantity-dependent durations should each refer to a base quantity of 1000 L. Duration, fixed
Act. type
Duration, variable
Act. type
(2nd std. value)
1420
10 min
1420
130
10 min
1420
140
10 min
1420
210
10 min
1420
230
10 min
1420
310
10 min
1420
20 min
1420
(1st std. value) 110 30 min
Use
30 min
5h
1420
330 a)
Creating
Only
Internal
320
1420
Partner
220
1420
SAP
SAP
120
Use
Partner
Phase
operations and phases and assigning resources Operations tab b)
Control key On the operation overview, Position the cursor on the control key Continued on next page
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Internal
Maintain the standard values for the phases of your recipe according to the information in the following table.
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Unit 7: Master Recipes (I)
PLM115
F4 input help In the control key overview: Position the cursor on the control key Choose Detailed Information. Which indicators are set? Scheduling
Only
Cost
Partner
Based on the indicators that have been set, what happens to a phase marked with this control key in the process order? The phase is scheduled
Use
Capacity requirement records are generated The costs of the phase are calculated c)
Text
SAP
SAP
Select operation 200 Choose the Text icon. d)
Administrative data
Use
Partner
Double-click the Operation/phase number Administrative Data tab On the Operations tab: Double-click the respective Phase Number Standard Values tab You can also maintain the standard values directly in the operation overview. 4.
a) Assigning a secondary resource Add the secondary resource T-DTT1## "Transport vehicle" for phase 330.
Continued on next page
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Only
Internal
e)
Internal
Det. Cap. Reqmnts
PLM115
Lesson: Creating Header and Operation Data
Sec.res.
Resource
Plant
Description
0001
T-DTT1##
1100
Discharge into transport unit
b) Text (for secondary resource) Enter the following text for your secondary resource.
Only
It cannot be detached until 10
Internal
Discharge into transport unit
Partner
Text: 15 minutes before charging begins the transport vehicle must be connected. minutes after charging is
Use
finished. c) Standard value and earliest and latest dates
SAP Use
45 min.
Offset to start:
15 min.
Offset to finish:
10 min.
Partner
Duration:
d) Administration data
Internal
SAP
Define the standard value and the earliest and latest dates of your secondary resource according to the following information.
Display the administrative data for your secondary resource.
Only
Continued on next page
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Unit 7: Master Recipes (I)
PLM115
Save your recipe. a)
Assigning a secondary resource On the Operations tab: Selection of phase 330 Secondary Resource icon
b)
Text
Only
Internal
On the Secondary Resources tab: Select the Secondary Resource Choose the Text icon.
Partner
c)
Standard value and earliest and latest dates Double-click the item number of the secondary resource
d)
Use
Standard Values tab Administrative data Administrative Data tab
SAP
SAP
5.
Relationships a) Graphical maintenance / maintenance by means of the Generate Relationships function
Only
Use Internal
Use graphical maintenance and/or the Generate Relationships function.
Figure 89: Graphical Maintenance
b) Maintenance on the phase detail screen Maintain the last relationship 320------330 in the detail screen for phase 320. Continued on next page
264
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Partner
Create the relationships between the phases of your recipe as shown in the following graphic.
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PLM115
Lesson: Creating Header and Operation Data
Successor
Phase
X
330
Relationship type
Rcp. grp
Recipe
T-DET1##
1
FS
Internal
Only
Finish - start
Display the detail information for this relationship. Choose the Detail icon for the relationship you created.
Partner
Display the administrative data for this relationship. Administrative Data tab
Use
c) Displaying information in graphical maintenance Go back to the graphic display of the relationships. Double-click a phase.
SAP
____________________
Use
Only
Internal
____________________
Partner
Double-click a line connecting two phases. Which relationship detail screen appears?
SAP
Which phase detail screen appears?
Continued on next page
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Unit 7: Master Recipes (I)
PLM115
Save your recipe. a)
Graphical maintenance: in the operation overview (Operations tab): Operation Graphic icon Maintained using the function Generate Relationships:
Only
Internal
in the operation overview (Operations tab):
Partner
b)
SAP
Generate Relationship icon
c)
Maintenance on the phase detail screen On the operation overview,
Use
Double-click phase number 320 Relationships tab
SAP
Displaying information in graphical maintenance Operations tab
Partner
Use
Operation Graphic icon Double-click a phase. Which phase detail screen appears?
Internal
Phase standard values Double-click a line connecting two phases.
Only
Which relationship detail screen appears? General relationship data
Task 2: Classifying operations 1.
Classify the operation 200 in the class REAC_## "Reaction vessel". Assign the following values to the characteristics: Continued on next page
266
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PLM115
Lesson: Creating Header and Operation Data
Surface coating
P
Revolutions per Min.
30
Save your master recipe.
a)
Internal
Only
Hint: The classification of the operation defines the selection conditions for a system-aided resource selection in the process order. On the Operations tab: Select operation 200
Partner
Icon Resource selection conditions or Goto → Res. sel. cond.
Task 3:
Use
Scheduling Suggestion: Do the following exercise for different charge quantities. Simulate order scheduling in your master recipe.
Display the result in the scheduling overview.
SAP
SAP
Scheduling overview
Use
1.
On the operation overview, Schedule Recipe icon
Partner
a)
On the operation overview,
Internal
Schedule Recipe icon 2.
Gantt chart Display the scheduling results in the Gantt chart.
Only
Choose the Gantt Chart icon. Select a suitable time unit. a)
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Choose the Gantt Chart icon.
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Unit 7: Master Recipes (I)
PLM115
Lesson Summary You should now be able to: • Create and maintain the header, operation, and phase data of a master recipe • Carry out scheduling in the master recipe
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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PLM115
Unit Summary
Unit Summary You should now be able to: • Describe the basic structure of a master recipe. • Create and maintain the header, operation, and phase data of a master recipe • Carry out scheduling in the master recipe
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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Unit Summary
PLM115
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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PLM115
Test Your Knowledge
Describe the structure of a master recipe. Name the most important elements.
2.
Name some important data that has to be maintained with reference to phases.
Use
Partner
1.
Internal
Only
Test Your Knowledge
SAP
SAP Only
Internal
Use
Partner
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Test Your Knowledge
PLM115
Answers 1.
Describe the structure of a master recipe. Name the most important elements. Answer:
Only
2.
Recipe header Operation overview: operations, resources, phases, relationships Material list: material components, material quantity calculation
Name some important data that has to be maintained with reference to phases.
• • • • •
Control key Standard values Relationships Control recipe destinations Process instructions
Use
Partner
Answer:
Internal
• • •
SAP
SAP Only
Internal
Use
Partner
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Unit 8 Unit Overview
Unit Objectives After completing this unit, you will be able to:
SAP Use
Unit Contents
Internal
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Only
Lesson: Materials in the Master Recipe ......................................... 274 Lesson: Creating BOM and Material List ........................................ 277 Exercise 14: Creating BOM and Material List .............................. 283 Lesson: Material Quantity Calculation ........................................... 291 Exercise 15: Material Quantity Calculation ................................. 295 Lesson: Example Scenario for Material Quantity Calculation................. 299
Partner
Describe the connection between recipe, BOM and material list Create a BOM for a master recipe Maintain the material list of a master recipe Classify BOM components Maintain formulas for material quantity calculation. Describe the use of the material quantity calculation using the example scenario presented.
SAP
• • • • • •
Use
Partner
This chapter introduces you to the maintenance of material components for a master recipe.
Internal
Only
Master Recipes (II)
Unit 8: Master Recipes (II)
PLM115
Lesson: Materials in the Master Recipe Lesson Overview This lesson introduces you to the connection between recipe, BOM and material list.
Lesson Objectives •
Describe the connection between recipe, BOM and material list
Business Example
Use
Partner
To map the production process onto the system in more detail, you must create the relevant master recipes and BOMs. You now find out about the basic connection between recipe, BOM and material list.
Internal
Only
After completing this lesson, you will be able to:
Typical Material Flow in the Process Industry
SAP
SAP Only
Internal
Use
Partner
Figure 90: Typical Material Flow in the Process Industry
The graphic uses two examples of operations carried out at the primary resources charge vessel and reaction vessel to show a typical material flow in process manufacturing.
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Lesson: Materials in the Master Recipe
The graphic shows: • •
•
Use
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Recipe, BOM, and Material List
Internal
Only
• •
Ingredients entering the production process The temporary appearance of an intermediate product between two processing units, which continues to be processed without leaving the process. Such materials are assigned material type INTR Intra material. By-products produced during the manufacturing process The use of a catalyst that enters the process at a certain point of time and leaves it again later. The manufacture of one or more products If several planned materials are manufactured during one production run, they are called co-products.
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Figure 91: Recipe, BOM, and Material List
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Lesson Summary You should now be able to: • Describe the connection between recipe, BOM and material list
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Lesson: Creating BOM and Material List
Lesson: Creating BOM and Material List Lesson Overview This lesson introduces you to the maintenance activities for creating BOM and material lists.
Lesson Objectives
Only
Create a BOM for a master recipe Maintain the material list of a master recipe Classify BOM components
Business Example After having maintained the header, operation, and phase data, you now create the material BOM for your master recipe. In the material list, you then assign the material components to your phases.
SAP
SAP
For batch determination and material quantity calculation, you classify the relevant BOM items.
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• • •
Internal
After completing this lesson, you will be able to:
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Creating Master Recipes and BOMs (II)
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Internal
Figure 92: Creating Master Recipes and BOMs (II)
SAP
SAP
Bill of Material: Example
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Figure 93: Bill of Material: Example
The graphic shows the structure of a bill of material (BOM) for a material.
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Lesson: Creating BOM and Material List
The product is assigned to the BOM header. A base quantity is defined in the BOM header and the quantities of the material components entered in the BOM items refer to this base quantity. BOM items are, for example: •
Ingredients, intra materials, catalyst, by-products, co-products
Only Partner
If a BOM item is a co-product, the corresponding indicator must be set for this item. In addition to this, the co-product assigned to the BOM header as well as the co-products listed as BOM items must be marked as co-products in their material master records. Material BOM data is, for example, important for: Material requirements planning Material staging during production Product costing
Use
• • •
SAP
BOM Item Categories
SAP
Internal
Quantities of materials entering the production process are maintained with a positive number, quantities of materials leaving the process with a number followed by a negative sign. Materials that both enter and leave the process are assigned two different BOM items with the corresponding signs.
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Figure 94: BOM Item Categories
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A BOM item category specifically designed for the process industry is category “M” for intra materials. The item category determines, for example:
Only
Whether you must enter a material number Whether quantity-based inventory management is to be carried out for this item Which sign is to be entered for the item quantity Whether subitems can be used What the screen selection and the screen layout of the item detail screens look like
Partner
Note that you cannot change the item category once you have created an item. You can only correct a wrong item category assignment by deleting the item and creating it again.
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Material List
Internal
• • • • •
SAP
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Internal
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Figure 95: Material List
In the material list, the material components of the BOM are assigned to the phases according to their appearance in the process. A specific material list component is assigned to exactly one phase. You can assign several different material components to a phase.
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Lesson: Creating BOM and Material List
Classification of BOM Components
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Figure 96: Classification of BOM Components
SAP Use
The characteristic values defined in the process order are used as selection criteria during batch determination.
Only
Internal
The characteristic values can be used in the formulas of material quantity calculation.
Partner
BOM components are classified for the purpose of batch determination and material quantity calculation:
SAP
BOM components can be classified with class type batch in the master recipe. You thus store specific attributes that the planned material components must possess in the form of characteristic values for individual BOM items.
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PLM115
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Lesson: Creating BOM and Material List
Exercise 14: Creating BOM and Material List Exercise Objectives
Business Example
In the material list, you then assign the material components to your phases. For batch determination and material quantity calculation, you classify the relevant BOM items.
Task 1:
SAP
1.
Your master recipe T-DET1## describes the production of the material T-FD1##. Check the material assignment in the recipe header.
Use
Partner
When was the material assignment for the recipe defined? ____________________________________________________________
Internal
Task 2: Creating BOM and material list for material assigned
Only
Now create the BOM and material list with reference to the assigned material T-FD1##. 1.
BOM for material T-FD1## First, go to the Materials tab in your recipe. The initial screen for BOM maintenance appears. After releasing the data (Enter), you can assign the required material components in the BOM. Make the following assignments: Continued on next page
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Material-recipe assignment
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After having maintained the header, operation, and phase data, you now create the material BOM for your master recipe.
Internal
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After completing this exercise, you will be able to: • Create a BOM for a master recipe • Maintain the material list of a master recipe • Classify BOM components
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Item
ICt
Component
Quantity
0010
L
T-RD1##
975 L
0020
L
T-RD2##
400 L
0030
N
T-RD3##
1,225 L
0040
L
T-RD4##
1,000 L
0050
L
T-RD5##
1400 L
Enter 5000 L as the base quantity in the BOM header. Choose the Header icon. Material list for material T-FD1## Choose F3 "Back".
T-RD1##
110
SAP
T-RD2##
110
T-RD3##
130
T-RD4##
220
T-RD5##
220
Partner
Phase
SAP
Component
Use
The material list for the recipe (Materials view) appears. Assign the material components to the phases of your recipe according to the following table:
Task 3: Checking the production version Perform a consistency check for production version 0001 of your material T-FD1##. Which information appears in the consistency log? ____________________________________________________________ ____________________________________________________________ What is the new check status for the production version? Continued on next page
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Internal
Save your recipe.
1.
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2.
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Unit 8: Master Recipes (II)
PLM115
Lesson: Creating BOM and Material List
____________________________________________________________
Task 4: Classification of BOM components 1.
In your master recipe T-DET1##, classify the BOM component T-RD1##.
Only
Which class of class type 023, Batch is assigned to the BOM item?
Partner
Why? ______________________________________________________ ______________________________________________________
Use
40 – 50 %
Density
1.3000 - 1.4000 g/ccm
SAP
SAP
Define the following values for the class characteristics as batch selection conditions: Concentration
Internal
Hint: You must classify the BOM components so you can carry out system-aided batch determination in the process order.
Save your master recipe.
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Internal
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Solution 14: Creating BOM and Material List Task 1: Material-recipe assignment 1.
Your master recipe T-DET1## describes the production of the material T-FD1##. Check the material assignment in the recipe header.
Only
____________________________________________________________ a)
Use the Production Version transaction to access your recipeT-DET1##. Choose the Recipe Header tab Choose Material Assignments. Material assignment was defined when production version 0001 for material T-FD1## was created.
SAP
Creating BOM and material list for material assigned
Use
1.
BOM for material T-FD1## First, go to the Materials tab in your recipe.
Item
ICt
Component
Quantity
0010
L
T-RD1##
975 L
0020
L
T-RD2##
400 L
0030
N
T-RD3##
1,225 L
0040
L
T-RD4##
1,000 L
0050
L
T-RD5##
1400 L
Only
Internal
The initial screen for BOM maintenance appears. After releasing the data (Enter), you can assign the required material components in the BOM. Make the following assignments:
Continued on next page
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Partner
Now create the BOM and material list with reference to the assigned material T-FD1##.
SAP
Task 2:
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In the recipe,
Internal
When was the material assignment for the recipe defined?
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Lesson: Creating BOM and Material List
Enter 5000 L as the base quantity in the BOM header. Choose the Header icon. a)
Go to the Materials tab in your recipe. Screen: Create Material BOM: Initial Access Choose Enter. Enter the material components
Only
Choose the Header icon. 2.
Material list for material T-FD1##
T-RD1##
110
SAP
T-RD2##
110
T-RD3##
130
T-RD4##
220
T-RD5##
220
Partner
Phase
SAP
Component
Use
The material list for the recipe (Materials view) appears. Assign the material components to the phases of your recipe according to the following table:
Save your recipe.
Internal
a)
In the BOM header,choose F3 (Back). Materials tab
Only
For the individual slides: Choose the Create Assignment icon.
Task 3: Checking the production version 1.
Perform a consistency check for production version 0001 of your material T-FD1##. Which information appears in the consistency log? Continued on next page
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Choose F3 "Back".
Internal
to enter the base quantity:
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Unit 8: Master Recipes (II)
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____________________________________________________________ ____________________________________________________________ What is the new check status for the production version? ____________________________________________________________ a)
In the mass maintenance for production versions:
Only
Check status:
Internal
Consistency log:
Partner
Choose the Consistency Check icon. Task list is available (no warning or errors) BOM is available (no warning or errors) Check without errors (green traffic light)
Use
Task 4: Classification of BOM components
SAP
In your master recipe T-DET1##, classify the BOM component T-RD1##.
Partner
Use
Hint: You must classify the BOM components so you can carry out system-aided batch determination in the process order. Which class of class type 023, Batch is assigned to the BOM item? Why? ______________________________________________________ Define the following values for the class characteristics as batch selection conditions: 40 – 50 %
Density
1.3000 - 1.4000 g/ccm
Continued on next page
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Internal
______________________________________________________
Concentration
SAP
1.
PLM115
Lesson: Creating BOM and Material List
Save your master recipe. a)
In your master recipe T-DET1##, classify the BOM component T-RD1##. (…) → Production Versions Select production version 0001. Choose Recipes.
Only
Select T-RD1##. Extras → Batch classification. Why? 023_14 Raw material T-RD1## was classified in this class in the "Aspects of Batch Management“ unit..
SAP
SAP
The BOM item inherits the classification from the material master.
Use
Which class of class type 023, Batch is assigned to the BOM item?
Internal
Choose BOM.
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Materials tab
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Unit 8: Master Recipes (II)
PLM115
Lesson Summary You should now be able to: • Create a BOM for a master recipe • Maintain the material list of a master recipe • Classify BOM components
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Internal
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PLM115
Lesson: Material Quantity Calculation
Lesson: Material Quantity Calculation Lesson Overview This lesson introduces you to material quantity calculation.
Lesson Objectives •
Maintain formulas for material quantity calculation.
Business Example
Partner
In material quantity calculation, you then define the formulas for calculating the product quantity, component quantities, and operation and phase quantities.
Use
Material Quantity Calculation
Internal
Only
After completing this lesson, you will be able to:
SAP
SAP Only
Internal
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Figure 97: Material Quantity Calculation
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In material quantity calculation, you define formulas to calculate the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the ingredients, yield ratios of the products and by-products as well as specific batch characteristic (for example, concentration). You can also define formulas for calculating phase quantities in material quantity calculation.
Internal
Only
By using batch determination together with material quantity calculation, you can perform active ingredient management in a process order.
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Material Quantity Calculation Screen
SAP
SAP
The numbers in brackets define a "cell" consisting of line and column numbers (see key).
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Figure 98: Material Quantity Calculation Screen
PLM115
Lesson: Material Quantity Calculation
The detail functions of material quantity calculation are: •
Choose the Formula icon This function selects the cell on which you have positioned the cursor and enters it in the formula section of the screen.
•
Insert in Formula icon
•
Save Formula icon This function saves formulas but does not transfer the values into the material list.
Partner
•
Save Formula and Copy Result Saves all formulas and then transfers the values to the material list and BOM.
•
This function contains the quantities and value fields plus the corresponding formulas. References used in the formulas are replaced by the value and the description of the field to which they refer. Calculate Product Quantity
SAP
SAP
Formula Overview icon
Use
•
Internal
Only
This function copies the coordinates of line and column in the formula section, such as [003,001].
The system calculates the product quantity and subsequently updates all component, operation, phase, and scrap quantities for which formulas have been defined.
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Unit 8: Master Recipes (II)
PLM115
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Internal
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PLM115
Lesson: Material Quantity Calculation
Exercise 15: Material Quantity Calculation Exercise Objectives After completing this exercise, you will be able to: • Define formulas for material quantity calculation
Only
Material Quantity Calculation
Task: 1.
Go to material quantity calculation in your master recipe.
Use
First, position the cursor on the formula field and choose input help (F1). Comprehensive information on material quantity calculation is displayed.
SAP Use
You obtain the quantity of phase 130 by adding the quantities of components T-RD1##, T-RD2## and T-RD3##. (...) Save the formulas and your recipe.
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The quantity of phase 120 corresponds to the quantity of phase 110.
You obtain the quantity of phase 110 by adding the quantities of components T-RD1## and T-RD2##.
Partner
Examples:
Internal
Familiarize yourself with formula maintenance in material quantity calculation by defining, for example, formulas for phase quantity calculation.
SAP
Then, familiarize yourself with the individual elements and functions of material quantity calculation. To do so, use the information provided on the relevant pages in your participant handbook. 2.
Internal
In material quantity calculation, you then define the formulas for calculating the product quantity, component quantities, and operation and phase quantities.
Partner
Business Example
Unit 8: Master Recipes (II)
PLM115
Solution 15: Material Quantity Calculation Task: Material Quantity Calculation 1.
Go to material quantity calculation in your master recipe.
Then, familiarize yourself with the individual elements and functions of material quantity calculation. To do so, use the information provided on the relevant pages in your participant handbook.
2.
In the material list for your master recipe, choose the Material quantity calculation (a/b) icon.
Familiarize yourself with formula maintenance in material quantity calculation by defining, for example, formulas for phase quantity calculation. Examples:
SAP
The quantity of phase 120 corresponds to the quantity of phase 110.
Use
Only
Internal
(...)
Partner
You obtain the quantity of phase 130 by adding the quantities of components T-RD1##, T-RD2## and T-RD3##.
SAP
You obtain the quantity of phase 110 by adding the quantities of components T-RD1## and T-RD2##.
Use
Partner
a)
Internal
Only
First, position the cursor on the formula field and choose input help (F1). Comprehensive information on material quantity calculation is displayed.
Continued on next page
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Lesson: Material Quantity Calculation
Save the formulas and your recipe. a)
Example : Calculation of the quantity of phase 110: Position the cursor in the quantity field of phase 110 (row 3, column 1). Choose Select formula.
Only
The connection applies: Quantity Phase 110 = Quantity T-RD1## + Quantity T-RD2##
Partner
To define this formula, you can proceed as follows: Position the cursor in the quantity field of component T-RD1## (row 4, column 1).
Internal
You can now enter the formula for phase quantity calculation in the formula field.
Use
Choose Insert in Formula. The formula field now states: [004,001]
SAP
Position the cursor in the quantity field of component T-RD2## (row 5, column 1).
Use
The formula field now contains the complete formula: [004,001] + [005,001]
Internal
Check the result.
SAP
Choose the operand + . The formula field now states: [004,001] +
Choose Insert in Formula.
Partner
Choose Save Formula and call up the material quantity calculation again.
Only
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Lesson Summary You should now be able to: • Maintain formulas for material quantity calculation.
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Lesson: Example Scenario for Material Quantity Calculation
Lesson: Example Scenario for Material Quantity Calculation Lesson Overview This lesson familiarizes you with an example scenario for using the material quantity calculation.
Only
After completing this lesson, you will be able to: Describe the use of the material quantity calculation using the example scenario presented.
Business Example
Batch Determination and Material Quantity Calculation: General Process
SAP
SAP
You have to use the material quantity calculation in collaboration with the batch determination and using proportion units, in order to represent special processes of the active ingredient management.
Use
Partner
•
Internal
Lesson Objectives
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Internal
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Figure 99: Batch Determination and Material Quantity Calculation: General Process
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Master Recipe for Sample Scenario
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Figure 100: Master Recipe for Sample Scenario
SAP
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Lesson: Example Scenario for Material Quantity Calculation
Batch Determination and Material Quantity Calculation: Sample Scenario (I)
Use
After the process order has been created, batch determination is carried out for the Fruit premix component in our scenario. Batch determination settings specify that the batches must always be used up. The batches are available in containers of 1200 L. You must withdraw enough containers so that you do not fall below the planned production quantity. An overdelivery is allowed.
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Internal
In our scenario, the values of the Fruit content and Acidity characteristics of the Fruit juice product are the fixed target values of production. All other values are variable.
Partner
After the process order has been created, the planned quantities and planned characteristic values for the Fruit juice product and the material components are available.
SAP
SAP
Use
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Internal
Figure 101: Batch Determination and Material Quantity Calculation: Sample Scenario (I)
Unit 8: Master Recipes (II)
PLM115
Batch Determination and Material Quantity Calculation: Sample Scenario (II)
SAP
Only
Internal
Partner
Since production requirements make it necessary to withdraw more fruit premix and since the characteristic values of the assigned batch deviate from the planned values, material quantity calculation must be used to recalculate the production quantities for the Fruit juice, the proportion quantities for the Lemon juice, and the Sugar and Water quantities.
SAP
Use
Use
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Internal
Figure 102: Batch Determination and Material Quantity Calculation: Sample Scenario (II)
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Lesson: Example Scenario for Material Quantity Calculation
Batch Determination and Material Quantity Calculation: Sample Scenario (III)
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Only
Internal
Partner
Afterwards, batch determination is carried out for the Citric acid based on the recalculated proportion quantity. In our scenario, the required quantity is charged from a big storage tank.
SAP
SAP
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Internal
Figure 103: Batch Determination and Material Quantity Calculation: Sample Scenario (III)
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Batch Determination and Material Quantity Calculation: Sample Scenario (IV)
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Internal
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Then material quantity is used to recalculate the Water quantity that needs to be added based on the production quantity (Fruit juice) and the added quantities of Fruit premix and Lemon juice.
SAP
SAP
Use
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Internal
Figure 104: Batch Determination and Material Quantity Calculation: Sample Scenario (IV)
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Lesson: Example Scenario for Material Quantity Calculation
Formulas for the Sample Scenario (I)
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Internal
SAP
SAP
Figure 105: Formulas for the Sample Scenario (I)
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Unit 8: Master Recipes (II)
PLM115
Formulas for the Sample Scenario (II)
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SAP
SAP
Figure 106: Formulas for the Sample Scenario (II)
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Lesson: Example Scenario for Material Quantity Calculation
Lesson Summary You should now be able to: • Describe the use of the material quantity calculation using the example scenario presented.
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SAP
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Unit Summary
PLM115
Unit Summary
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Use
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Internal
You should now be able to: • Describe the connection between recipe, BOM and material list • Create a BOM for a master recipe • Maintain the material list of a master recipe • Classify BOM components • Maintain formulas for material quantity calculation. • Describe the use of the material quantity calculation using the example scenario presented.
SAP
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Test Your Knowledge
Partner
2.
Name the basic steps in reference to the creation of BOMs and material lists for a master recipe in the context of integrated BOM maintenance.
3.
Which quantity information can you calculate by means of the material quantity calculations?
4.
Describe the basic procedure of a material quantity calculation in collaboration with the batch determination.
Only
Internal
Partner
Use
SAP
SAP
Name some typical cases in the context of the material flow in process manufacturing.
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1.
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Test Your Knowledge
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Test Your Knowledge
PLM115
Answers 1.
Name some typical cases in the context of the material flow in process manufacturing. Answer:
Only Partner
2.
Ingredients entering the production process By-products produced during the manufacturing process Manufacture of a product Manufacture of several co-products
Name the basic steps in reference to the creation of BOMs and material lists for a master recipe in the context of integrated BOM maintenance.
SAP Use Internal
• • •
– Maintain material components – Maintain header data Navigate in master recipe Maintain material list If req., maintain material quantity calculation
Which quantity information can you calculate by means of the material quantity calculations? Answer:
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• • • •
Product quantities Material component quantities Co-product and by-product quantities Operation and phase quantities
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Master recipe: navigation in BOM Create material BOM
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3.
• •
Use
Answer:
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• • • •
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Test Your Knowledge
4.
Describe the basic procedure of a material quantity calculation in collaboration with the batch determination. Answer: •
Master recipe: Definition of formulas for the material quantity calculation
•
Creating a process order:
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•
Batch determination and subsequent material quantity calculation:
Partner
Adjusting the order quantities (components, product, operations, phases) for deviations in the batch characteristics •
Internal
Selecting the master recipe and the material quantity calculation with planned values
Material staging and process order execution
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Unit Summary
PLM115
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Unit 9 Unit Overview
Unit Objectives After completing this unit, you will be able to:
SAP
Describe the principle of process management Maintain control recipe destinations and process instructions in the master recipe Design a simple PI sheet in the master recipe Use reporting and mass processing functions for master recipes and BOMs Copy master recipes across plants
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Lesson: Process Management: Overview....................................... 314 Lesson: Maintenance of Process Instructions .................................. 317 Exercise 16: Maintenance of Process Instructions ........................ 325 Lesson: Reporting, Mass Processing and Copying ............................ 351 Exercise 17: Reporting, Mass Processing and Copying .................. 355
Partner
Unit Contents
SAP
• • • • •
Use
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This chapter introduces you to the maintenance of process instructions for a master recipe.
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Master Recipes (III)
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Lesson: Process Management: Overview Lesson Overview This lesson provides an overview of the principle of process management.
Lesson Objectives •
Describe the principle of process management
Business Example
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You want to use the process management functions to link process control systems to your system and create PI sheets. Find out about the principle of process management first.
Internal
Only
After completing this lesson, you will be able to:
Process Management
SAP
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Internal
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Figure 107: Process Management
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Lesson: Process Management: Overview
Process management is the interface between PP-PI and the systems involved in process control. Due to its flexible structure, it can be linked to fully automated, partially automated, and manually operated lines. Process management comprises the following functions: •
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•
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•
Internal
•
Receiving control recipes with process instructions from released process orders The process instructions define, for example, the process steps to be executed and the process data to be confirmed (using process messages) in more detail. Transferring control recipes to the corresponding process operators or process control systems. If a process operator processes the control recipe manually: Displaying control recipes in natural language in the form of PI sheets that can be displayed and maintained on the screen by the process operator Receiving, checking, and sending process messages with actual process data from the process control system or the PI sheet
Data is exchanged with process control systems using the PI-PCS interface.
SAP
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Lesson Summary You should now be able to: • Describe the principle of process management
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Lesson: Maintenance of Process Instructions
Lesson: Maintenance of Process Instructions Lesson Overview This lesson introduces you to the possible maintenance alternatives for process instructions.
Only
Maintain control recipe destinations and process instructions in the master recipe Design a simple PI sheet in the master recipe
You want to use the process management functions to link process control systems to your system and create PI sheets. For this, you must maintain the corresponding data structures for process control in the form of process instructions in your master recipes.
SAP
SAP
For manually operated processes, you design PI sheets.
Alternatives of Process Instruction Maintenance
Use
Alternative 1 (All Releases)
•
Presetting the process instruction types in Customizing Maintenance of the process instructions based on copied process instructions for the phases of the recipe/process order – Assigning the control recipe destinations to the phases – Definition of process instructions to be generated for the control recipe destinations in Customizing. Alternative 2 (As of SAP R/3 ERP and SCM Extension 2.00) – – –
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Maintenance of all process instructions in XSteps (Execution Steps) in the XStep Editor of the recipe/process order Option of copy of reference of standard XSteps from the Standard XStep Repository Assigning the control recipe destination and maintenance of the generation scope, context and parameters for the XSteps
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Internal
– –
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•
Use
Business Example
• •
Internal
After completing this lesson, you will be able to:
Partner
Lesson Objectives
Unit 9: Master Recipes (III)
PLM115
Generating Control Recipes: Alternative 1
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Only
Internal
A control recipe destination and any number of process instructions are assigned to each phase of master recipe. (Automatically Generated Process Instruction can also be assigned directly to the control recipe destinations in Customizing.)
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Only
Internal
For a released order, process management bundles the process instructions into control recipes and transfers them to the relevant destination.
Partner
To execute an actual production process, a process order is created on the basis of a master recipe. Together with the control recipe destinations and process instructions, the operation and phase structure is taken over from the master recipe.
SAP
SAP
Figure 108: Generating Control Recipes: Alternative 1
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Lesson: Maintenance of Process Instructions
Maintenance Activities in the Recipe: Alternative 1
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Partner
Only
Internal
SAP Use
Only
Internal
For the process instructions required in the recipe, you define process instruction categories in Customizing. When you create a process instruction in the recipe, you must choose a process instruction category from Customizing as the template to copy from. You can then tailor it according to the corresponding process.
Partner
You create and maintain control recipe destinations in Customizing. In the master recipe, you assign the suitable control recipe destination from Customizing as a reference per phase.
SAP
Figure 109: Maintenance Activities in the Recipe: Alternative 1
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Generating Control Recipes: Alternative 2
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Internal
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Internal
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As of SAP R/3 ERP and SCM Extension 2.00 (EA_APPL_2.00) the data for process management can alternatively be maintained in the form of XSteps (Execution Steps). The use of XSteps enables the maintenance of process instructions in the form of reusable modules that can be referenced. A Standard XStep Repository with version management is available.
SAP
Figure 110: Generating Control Recipes: Alternative 2
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Lesson: Maintenance of Process Instructions
Maintenance Activities in the Recipe: Alternative 2
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Internal
SAP
In the XStep Editor of the master recipe, you create the required process instructions for XSteps.
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When you create XSteps, you can reference standard XSteps from the Standard XStep Repository.
Partner
An XSteps also includes information on the control recipe destination of the process instructions, the phase assignment and the scope of generation.
SAP
Figure 111: Maintenance Activities in the Recipe: Alternative 2
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PI Sheet
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Internal
The SAP PI sheet provides for processing on the screen, which means the process operator is to enter, confirm, or complete data interactively.
Use Internal
Display of information on process (control instructions, notes, and so on) Input fields and tables for entering process data, input validations, signatures Batch determination and batch check Process data calculation Function calls for calling data from internal or external applications Navigation to QM inspection results recording Sequence definition for determining the processing sequence of phases Comments on documentation and reporting of process events
As of Release 4.6C, you can generate PI sheets in HTML. The browser-based PI sheet enhances the ABAP list-based PI sheet. It gives you the advantage of a flexible, user-specific layout definition and allows you to define frames, for example, for linking to documents, graphics, the internet and intranet.
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• • • • • • • •
Partner
Depending on the process instructions contained in a control recipe, the PI sheet has the following elements and functions, for example:
SAP
SAP
Figure 112: PI Sheet
PLM115
Lesson: Maintenance of Process Instructions
PI Sheet Simulation in the Master Recipe
Partner
The effects process instructions and their characteristics have on the layout and structure of the PI sheet become visible only after the control recipe has been created. To check the PI sheet beforehand, you can simulate a PI sheet in the master recipe.
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Figure 113: PI Sheet Simulation in the Master Recipe
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Lesson: Maintenance of Process Instructions
Exercise 16: Maintenance of Process Instructions Exercise Objectives
Only
Business Example
For this, you must maintain the corresponding data structures for process control in the form of process instructions in your master recipes. For manually operated processes, you design PI sheets.
SAP
SAP
Task 1: Alternative 1: maintenance on the process instructions for the phases Control recipe destinations and process instructions
Use
2.
Display the operation overview for recipe 1 of the recipe group COLORS. Control recipe destinations Which control recipe destinations have been assigned to the phases of the recipe?
Internal
Choose input help (F4) on the Destination field. CtrRecDest Description of control recipe destination
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____ __________________________________ ____ __________________________________ 3.
Process instructions Which process instruction categories are assigned to phase 1010? On the operation overview, Icon Process Instructions for phase 1010 process instruction type Continued on next page
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1.
Use
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You want to use the process management functions to link process control systems to your system and create PI sheets.
Internal
After completing this exercise, you will be able to: • Maintain the data structures for process management in the master recipe • Develop the concept for a simple PI sheet in the master recipe based on preset data structures
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___________________________ ___________________________ ___________________________ 4.
Process instruction characteristics Which process instruction characteristics are assigned to the process instruction INSTR?
Only
______________________________ ______________________________
Partner
The characteristics PPPI_INSTRUCTION and PPPI_NOTE are each assigned a long text. Display the long texts.
Internal
Choose the Process Instruction Details icon.
Choose Value.
Use
5.
PI sheet simulation Simulate the PI sheet for the phases with control recipe destination 01.
SAP
SAP
On the operation overview, Choose the Simulate PI Sheet icon.
Task 2:
Use
1.
Create process instructions for your recipe T-DET1## according to the information in the following table.
Hint: The process instructions required for reporting material movement and order dates as well as other process instructions with information on operations, phases, and material components are all defined as automatically generated process instructions for the control recipe destination DE. In this exercise, you only have to define process instructions for work instructions and notes for process operators. Continued on next page
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Check and correct the texts and remove the process instruction characteristics you do not need.
Partner
Defining a PI sheet in recipe T-DET1##
PLM115
Lesson: Maintenance of Process Instructions
Caution: Delete all PPPI_NOTE characteristics to which you do not assign long texts. Characteristics without values cause errors in control recipe creation!
PI
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction) Long text (ZT-DET100-1):
SAP Use
Caution! Corrosive material! Wear protective clothes, gloves, and protective mask. Phase 120: PI
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction)
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Long text (ZT-DET100-2):
Partner
PPPI_NOTE (note)
SAP
Long text (ZT-DET100-1): Fill the required quantity of raw materials T-RD1## (sulfuric acid) and T-RD2## (lauryl alcohol) into the charging tank and confirm the filled quantity. Pay attention to the safety instructions.
Use
Partner
Phase 110:
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Hint: The control instructions and notes are defined as standard texts in the system. You can insert these texts in the long text editor (see Solutions).
Unit 9: Master Recipes (III)
PLM115
Long text (ZT-DET100-3): Turn on agitator. Mix ingredients for 10 min.
PI
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction)
Partner
Long text (ZT-DET100-4): Add displayed quantity of water to mixture.
Use
PI
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction)
Use
Phase 220: PI
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction)
Continued on next page
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Internal
Transfer material from charging tank to reaction tank. Start agitator.
Partner
Long text (ZT-DET100-5):
SAP
SAP
Phase 210:
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Phase 130:
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Lesson: Maintenance of Process Instructions
Long text (ZT-DET100-6):
Internal
Only
Carefully add the required raw materials T-RD4## (1 butanol) and T-RD5## (sodium hydroxide) to the reaction vessel. Confirm consumed quantities. Mix for 10 minutes. Pay attention to the safety instructions. PPPI_NOTE (note)
Caution! Wear protective clothes, gloves, and protective mask.
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction) Long text (ZT-DET100-8):
Phase 330: PI
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction)
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Internal
Transfer the contents from the reaction vessel to the cooling vessel.
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Use
PI
SAP
SAP
Phase 310:
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Long text (ZT-DET100-7):
Unit 9: Master Recipes (III)
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Long text (ZT-DET100-9):
Internal
Only
Fill the product you just produced into the transport vehicle and confirm the quantity produced. Check if the cooling tank is empty and close the valves. PPPI_NOTE (note)
Partner
Long text (ZT-DET100-10): Wear protective clothing and gloves!
Use
20
DE_PROD
SAP
SAP
Simulate your PI sheet. Save your recipe.
Use
Task 3: In the following exercises, we want to carry out a complete process order execution based on the master data created in the previous exercises. 1.
Creating process order Create a process order of the order type PI01 for material T-FD1## (detergent) in production plant 1100. Total quantity:
(for example) 10000L
Basic dates: Finish
(for example) today + 1 week Continued on next page
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Internal
Double-click the control recipe destination
Partner
Hint: For more information, display the process instructions that are automatically generated in Customizing for the control recipe destination.
PLM115
Lesson: Maintenance of Process Instructions
Choose Enter and pay attention to the messages in the status bar. The master recipe T-DET1## (detergent production) is copied along with the material list and the process order is scheduled. On the Operation Overview and Material List screens, check whether the data from the master recipe T-DET1## has been copied correctly. Check whether the quantity fields for which you have defined formulas in material quantity calculation in the last chapter have been calculated correctly.
Only
System-aided batch determination Preliminary notes:
Partner SAP
Execute batch determination for component T-RD1## in the order.
Use
Choose the batch selected.
Pay attention to the message on the type of batch selection. Choose Enter to confirm the message.
Partner
Save your order and write down the order number. __________________.
Internal
3.
System-aided resource selection Preliminary notes:
Only
In the previous exercises, you classified your reaction vessel in the class REAC_## "Reaction vessel" of the class type 019 "Work center class" and defined specific properties for these resources by assigning values to the characteristics assigned. The resource T-DTG1## that is assigned to operation 200 only serves planning purposes (task list usage C## "Recipe until release, grp##"). An order cannot be released with this resource. Before an order can be released, the preliminary or dummy resource must be replaced with a suitable real resource.
Continued on next page
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You also classified the BOM item T-RD1## in the BOM for material T-FD1## with the same class. For the characteristics, you defined selection conditions for system-aided batch determination.
Use
In the previous exercises, you posted batch stocks for your material component T-RD1## which is subject to batch management requirement. The batches are classified in the class 023_14 (Detergent production) of the class type 023 "Batch". The characteristics M100 "Concentration" and M200 "Density" are assigned to class 023_14 to which you assigned the corresponding batch characteristics.
Internal
2.
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You also classified operation 200 with the class REAC_## and, by assigning the corresponding values to the characteristics, defined selection conditions for system-aided resource selection. The resource network is taken into account. Execute a resource selection for operation 200. Select one of the resource proposed. 4.
Releasing process order
Only
6.
Internal
5.
Partner
Release your order. Generating a control recipe Create the control recipe for the order. Save your order. Sending the control recipe Send your recipe in the control recipe monitor.
Use
7.
Finding and maintaining the PI sheet Search for the PI sheet and maintain it.
SAP
Read the texts and notes that have been created in the PI sheet.
Use
Record the produced quantity of the product T-FD1##. 8.
Sending process messages In the message monitor, send the process messages that were created during the maintenance of the PI sheet.
9.
Checking the postings made and data updates Check in the process order whether material movements, confirmations, and posted were posted successfully.
Continued on next page
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Internal
Set the PI sheet to complete after the last signature.
Partner
Report the actual quantities withdrawn for raw materials T-RD1## und T-RD2##, T-RD3##, T-RD4##, and T-RD5## where applicable.
SAP
Confirm the start and finish of the maintenance of a phase with your signature. Sign with your user and confirm with your password.
PLM115
Lesson: Maintenance of Process Instructions
Task 4: Alternative 2: maintenance of the process instructions in XSteps 1.
Access the master recipe with XSteps In the Production Versions (C223) transaction, selection for the production versions for material T-FF9##. Access the master recipe for the production version XSDE.
Only
Profile Which instructions for process instruction maintenance are defined via the recipe profile?
Partner
Process instruction maintenance: _________________________ 3.
Is it possible to maintain the control recipe destination and process instructions for the phases of the recipe?
Use
______________________________________________ Where are the process instructions and control recipe destinations to be maintained in this recipe?
SAP
SAP
______________________________________________ 4.
XStep Editor Navigate to the XStep Editor of the recipe.
Use
Simulation of the PI sheet
Simulate the PI sheet. Compare the XSteps of the XStep tree to the simulated PI sheet. Hint: The process instructions on the material consumption and goods receipt cannot be generated in the simulation yet. 6.
Process instructions of an XSteps Expand the structure of the XSteps Work Instruction with Safety Safety Instructions. Continued on next page
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The process instructions in the XSteps define a PI sheet for control recipe destination FE Fertilizer.
Partner
First, get an overview of the XSteps used for the XStep tree Fertilizer Production. 5.
Internal
2.
Unit 9: Master Recipes (III)
PLM115
Information on the XStep: Which application context does the XStep have? Application context: ___________________________ To which control recipe destination is the XStep assigned? Destination type: ________________________________
Only
The process instruction elements define long text outputs.
Display the characteristics of the process instruction elements and Safety Instructions of the process instructions 'Work instructions with safety instructions.
Internal
Characteristics of the process instructions:
Partner
Destination: ___________________________________
Display the long texts. Standard XSteps In our example, the XSteps for the process instructions were created in the XStep Editor of the recipe.
SAP Use
Task 5:
1.
Creating process order Create a process order of the order type PI01 for material T-FF9## in production plant 1100. Choose a total quantity of 1000l and a basic finish date in the future. Before you confirm the entered data choose the Production Versions button and manually select production version XSDE to open the order. The order is immediately released based on the settings in the material master and the control recipe for the order is generated automatically. Continued on next page
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Internal
In the following exercises you can now execute the process order processing based on the recipe for production version XSDE of material T-FF9##.
Partner
Display the standard XSteps in the Repository (plant 1100). The XSteps used in the recipe are in the folder Fertilizer Production EN.
SAP
The other XSteps of the recipe are references to standard XSteps of the Standard XStep Repository.
Use
7.
PLM115
Lesson: Maintenance of Process Instructions
Save your order first. 2.
Display the XSteps in the order Display the XSteps of your order. Note that the standard XSteps were exploded and the generation rules executed. Simulate the PI sheet for the order. You can now carry out the following activities according to the preceding exercises:
Internal
Only
3.
• Send the control recipe • Edit the PI sheet
Partner
• Send process messages • Analyze the data in the process order
Use
SAP
SAP Only
Internal
Use
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Unit 9: Master Recipes (III)
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Solution 16: Maintenance of Process Instructions Task 1: Alternative 1: maintenance on the process instructions for the phases Control recipe destinations and process instructions
Only
Display the operation overview for recipe 1 of the recipe group COLORS. a)
Control recipe destinations and process instructions
Operations tab 2.
Control recipe destinations Which control recipe destinations have been assigned to the phases of the recipe? Choose input help (F4) on the Destination field.
SAP
SAP
CtrRecDest Description of control recipe destination ____ __________________________________ ____ __________________________________
Use
Choose F4 on the Destination field.
Partner
a)
CRD Description of control recipe destination 01 PI sheet for group 1
Internal
A1 PI sheet for group A1 3.
Process instructions
Only
Which process instruction categories are assigned to phase 1010? On the operation overview, Icon Process Instructions for phase 1010 process instruction type ___________________________ ___________________________
Continued on next page
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Partner
Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Display
Internal
1.
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Lesson: Maintenance of Process Instructions
___________________________ a)
INSTR READ2 SIGN
4.
Process instruction characteristics
Only
Choose the Process Instruction Details icon. ______________________________
Partner
______________________________ The characteristics PPPI_INSTRUCTION and PPPI_NOTE are each assigned a long text. Display the long texts.
Use
Choose Value. a)
PPPI_INSTRUCTION
SAP
SAP
PPPI_NOTE 5.
PI sheet simulation Simulate the PI sheet for the phases with control recipe destination 01.
Use
Partner
On the operation overview, Choose the Simulate PI Sheet icon. a)
Simulating PI sheet for control recipe destination 01:
Internal
Operations tab Select phases with control recipe destination 01.
Only
Choose the Simulate PI Sheet icon.
Task 2: Defining a PI sheet in recipe T-DET1## 1.
Create process instructions for your recipe T-DET1## according to the information in the following table.
Continued on next page
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Internal
Which process instruction characteristics are assigned to the process instruction INSTR?
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Check and correct the texts and remove the process instruction characteristics you do not need.
In this exercise, you only have to define process instructions for work instructions and notes for process operators.
Characteristics without values cause errors in control recipe creation!
SAP
PI
PI Characteristic
Use
ProcInstr type
10
INSTR
PPPI_INSTRUCTION (control instruction)
Long text (ZT-DET100-1): Fill the required quantity of raw materials T-RD1## (sulfuric acid) and T-RD2## (lauryl alcohol) into the charging tank and confirm the filled quantity. Pay attention to the safety instructions. PPPI_NOTE (note)
Continued on next page
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Internal
Long text (ZT-DET100-1):
Partner
Phase 110:
SAP
Hint: The control instructions and notes are defined as standard texts in the system. You can insert these texts in the long text editor (see Solutions).
Use
Partner
Caution: Delete all PPPI_NOTE characteristics to which you do not assign long texts.
Internal
Only
Hint: The process instructions required for reporting material movement and order dates as well as other process instructions with information on operations, phases, and material components are all defined as automatically generated process instructions for the control recipe destination DE.
PLM115
Lesson: Maintenance of Process Instructions
Long text (ZT-DET100-2): Caution! Corrosive material! Wear protective clothes, gloves, and protective mask.
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction) Long text (ZT-DET100-3): Turn on agitator. Mix ingredients for 10 min.
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction) Long text (ZT-DET100-4):
Phase 210: PI
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction)
Continued on next page
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Internal
Add displayed quantity of water to mixture.
Partner
Use
PI
SAP
SAP
Phase 130:
Use
Partner
PI
Internal
Only
Phase 120:
Unit 9: Master Recipes (III)
PLM115
Long text (ZT-DET100-5): Transfer material from charging tank to reaction tank. Start agitator.
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction) Long text (ZT-DET100-6):
SAP
Long text (ZT-DET100-7):
Phase 310: PI
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction)
Continued on next page
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Internal
Caution! Wear protective clothes, gloves, and protective mask.
Partner
Use
PPPI_NOTE (note)
SAP
Carefully add the required raw materials T-RD4## (1 butanol) and T-RD5## (sodium hydroxide) to the reaction vessel. Confirm consumed quantities. Mix for 10 minutes. Pay attention to the safety instructions.
Use
Partner
PI
Internal
Only
Phase 220:
PLM115
Lesson: Maintenance of Process Instructions
Long text (ZT-DET100-8): Transfer the contents from the reaction vessel to the cooling vessel.
ProcInstr type
PI Characteristic
10
INSTR
PPPI_INSTRUCTION (control instruction)
Partner
PI
Fill the product you just produced into the transport vehicle and confirm the quantity produced. Check if the cooling tank is empty and close the valves.
Use
PPPI_NOTE (note)
SAP
SAP
Long text (ZT-DET100-9):
Use
Partner
Long text (ZT-DET100-10):
Internal
Wear protective clothing and gloves! 20
DE_PROD
Only
Simulate your PI sheet.
Continued on next page
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Internal
Only
Phase 330:
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Unit 9: Master Recipes (III)
PLM115
Save your recipe. Hint: For more information, display the process instructions that are automatically generated in Customizing for the control recipe destination. Double-click the control recipe destination
Only
Defining a PI sheet in recipe T-DET1##
Internal
a)
Operations tab Select phases listed.
Partner
Choose the Process Instructions icon. Enter the process instruction. Choose the Process Instruction Details icon.
SAP Use
Insert → Text → Standard...
Internal
Enter text name ZT-DET100-* Set the “Expand immediately” indicator.
Only
To simulate your PI sheet, select all phases in the operation overview. Choose the Simulate PI Sheet icon.
Continued on next page
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Partner
Hint: The control instructions and notes are defined as standard texts in the system. You can call up these texts in the long text editor by choosing:
SAP
Caution: Delete all PPPI_NOTE characteristics to which you do not assign long texts. Characteristics without values cause errors in control recipe creation!
Use
Maintain control instructions or notes.
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PLM115
Lesson: Maintenance of Process Instructions
Task 3: In the following exercises, we want to carry out a complete process order execution based on the master data created in the previous exercises. 1.
Creating process order
Total quantity:
(for example) 10000L
Basic dates: Finish
(for example) today + 1 week
On the Operation Overview and Material List screens, check whether the data from the master recipe T-DET1## has been copied correctly. Check whether the quantity fields for which you have defined formulas in material quantity calculation in the last chapter have been calculated correctly.
SAP
Logistics → Production - Process → Process Order → Process Order → Create → With Material Navigation in the operation overview:
Use
Partner
Choose Operations. Navigation in the material list Choose Materials. System-aided batch determination Preliminary notes: In the previous exercises, you posted batch stocks for your material component T-RD1## which is subject to batch management requirement. The batches are classified in the class 023_14 (Detergent production) of the class type 023 "Batch". The characteristics M100 "Concentration" and M200 "Density" are assigned to class 023_14 to which you assigned the corresponding batch characteristics. You also classified the BOM item T-RD1## in the BOM for material T-FD1## with the same class. For the characteristics, you defined selection conditions for system-aided batch determination. Continued on next page
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Internal
2.
SAP
a)
Use
Partner
Choose Enter and pay attention to the messages in the status bar. The master recipe T-DET1## (detergent production) is copied along with the material list and the process order is scheduled.
Internal
Only
Create a process order of the order type PI01 for material T-FD1## (detergent) in production plant 1100.
Unit 9: Master Recipes (III)
PLM115
Execute batch determination for component T-RD1## in the order. Pay attention to the message on the type of batch selection. Choose Enter to confirm the message. Choose the batch selected. Save your order and write down the order number. __________________. a)
In the material list,
Only
For the selected batch, Choose Copy.
Partner
3.
System-aided resource selection In the previous exercises, you classified your reaction vessel in the class REAC_## "Reaction vessel" of the class type 019 "Work center class" and defined specific properties for these resources by assigning values to the characteristics assigned.
Use
SAP
The resource T-DTG1## that is assigned to operation 200 only serves planning purposes (task list usage C## "Recipe until release, grp##"). An order cannot be released with this resource. Before an order can be released, the preliminary or dummy resource must be replaced with a suitable real resource.
SAP
Use
Preliminary notes:
Internal
Choose the Execute Batch Determination icon for component T-RD1##.
You also classified operation 200 with the class REAC_## and, by assigning the corresponding values to the characteristics, defined selection conditions for system-aided resource selection. The resource network is taken into account.
Partner
Internal
Execute a resource selection for operation 200. Select one of the resource proposed. (…) → Process Order → Change
Only
a)
On the operation overview, Choose the Execute Resource Selection icon for operation 200. Select one of the resources proposed. 4.
Releasing process order Release your order. a)
Choose the Release icon in the upper icon bar. Continued on next page
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PLM115
Lesson: Maintenance of Process Instructions
5.
Generating a control recipe Create the control recipe for the order. Save your order. a)
6.
Choose the Generate Control Recipe icon.
Sending the control recipe Send your recipe in the control recipe monitor.
Only
7.
(…) → Process Management → Control Recipe → Control Recipe Monitor
Finding and maintaining the PI sheet Search for the PI sheet and maintain it.
Partner
Confirm the start and finish of the maintenance of a phase with your signature. Sign with your user and confirm with your password.
Use
Read the texts and notes that have been created in the PI sheet. Report the actual quantities withdrawn for raw materials T-RD1## und T-RD2##, T-RD3##, T-RD4##, and T-RD5## where applicable.
SAP
SAP
Record the produced quantity of the product T-FD1##. Set the PI sheet to complete after the last signature. a)
(…) → Process Management → PI Sheet → Find
Use
Choose Complete. Sending process messages
a) 9.
(…) → Process Management → Message → Message Monitor
Only
Internal
In the message monitor, send the process messages that were created during the maintenance of the PI sheet. Checking the postings made and data updates
Continued on next page
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Partner
Set the PI sheet to complete after the last signature. 8.
Internal
a)
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Unit 9: Master Recipes (III)
PLM115
Check in the process order whether material movements, confirmations, and posted were posted successfully. a)
(…) → Process Order → Display Header
Only
Display the Status that currently applies Note the Delivered Quantity
Internal
• •
Material list
Partner
• •
Display the Detail Data for the material components Note the Withdrawal quantities
Operation overview For some phases, navigate to the detail view for Dates Note the Confirmed Dates quantities
Use
• •
Goto → Costs → Analysis Get an overview of the cost updates in your order with regard to confirmations, material withdrawals and the goods receipt.
Task 4:
Use
1.
Access the master recipe with XSteps
Access the master recipe for the production version XSDE. a) 2.
Known procedure
Profile Which instructions for process instruction maintenance are defined via the recipe profile? Process instruction maintenance: _________________________ a)
Extras → Profile Process instruction maintenance: XSteps Continued on next page
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Internal
In the Production Versions (C223) transaction, selection for the production versions for material T-FF9##.
Partner
Alternative 2: maintenance of the process instructions in XSteps
SAP
SAP
•
PLM115
Lesson: Maintenance of Process Instructions
3.
Is it possible to maintain the control recipe destination and process instructions for the phases of the recipe? ______________________________________________ Where are the process instructions and control recipe destinations to be maintained in this recipe? ______________________________________________
4.
The maintenance of the process instructions and control recipe destination in XSteps has to occur in the XStep Editor of the recipe. Maintenance for the phases is not possible.
XStep Editor
Partner
Navigate to the XStep Editor of the recipe. First, get an overview of the XSteps used for the XStep tree Fertilizer Production. 5.
Choose the XSteps icon.
Use
a)
Simulation of the PI sheet
SAP
SAP
The process instructions in the XSteps define a PI sheet for control recipe destination FE Fertilizer. Simulate the PI sheet.
Hint: The process instructions on the material consumption and goods receipt cannot be generated in the simulation yet.
Internal
6.
XSteps → Simulate
Process instructions of an XSteps
Only
Expand the structure of the XSteps Work Instruction with Safety Safety Instructions. Information on the XStep: Which application context does the XStep have? Application context: ___________________________ To which control recipe destination is the XStep assigned? Destination type: ________________________________ Continued on next page
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Partner
Use
Compare the XSteps of the XStep tree to the simulated PI sheet.
a)
Internal
Only
a)
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Unit 9: Master Recipes (III)
PLM115
Destination: ___________________________________ Characteristics of the process instructions: Display the characteristics of the process instruction elements and Safety Instructions of the process instructions 'Work instructions with safety instructions. The process instruction elements define long text outputs. a)
The structure of the XStep can be expanded using the corresponding function of the context menu (right mouse button).
Partner
Characteristics of the process instructions:
General tab
Use
Application context: Phase 0110 Destination type: PI sheet Destination: fertilizer You get to the characteristics of the process instructions element via the context menu.
Use
7.
Standard XSteps
The other XSteps of the recipe are references to standard XSteps of the Standard XStep Repository. Display the standard XSteps in the Repository (plant 1100). The XSteps used in the recipe are in the folder Fertilizer Production EN. a)
(…) → Production – Process → Master Data → Standard XStep Repository
Continued on next page
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Internal
In our example, the XSteps for the process instructions were created in the XStep Editor of the recipe.
Partner
You then get to the long text editor via the corresponding pushbutton.
SAP
Double-click XStep
SAP
Information on the XStep:
Internal
Only
Display the long texts.
PLM115
Lesson: Maintenance of Process Instructions
Task 5: In the following exercises you can now execute the process order processing based on the recipe for production version XSDE of material T-FF9##. 1.
Creating process order Create a process order of the order type PI01 for material T-FF9## in production plant 1100. Before you confirm the entered data choose the Production Versions button and manually select production version XSDE to open the order.
Partner
The order is immediately released based on the settings in the material master and the control recipe for the order is generated automatically. Save your order first. 2.
See exercise description
Use
a)
Display the XSteps in the order Display the XSteps of your order.
SAP
Simulate the PI sheet for the order. (…) → Process Order → Display
Use
Partner
Choose XSteps. XSteps → Simulate
Internal
3.
You can now carry out the following activities according to the preceding exercises: • Send the control recipe
Only
• Edit the PI sheet • Send process messages • Analyze the data in the process order a)
2005/Q2
Known procedure
© 2005 SAP AG. All rights reserved.
SAP
Note that the standard XSteps were exploded and the generation rules executed. a)
Internal
Only
Choose a total quantity of 1000l and a basic finish date in the future.
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Unit 9: Master Recipes (III)
PLM115
Lesson Summary You should now be able to: • Maintain control recipe destinations and process instructions in the master recipe • Design a simple PI sheet in the master recipe
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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PLM115
Lesson: Reporting, Mass Processing and Copying
Lesson: Reporting, Mass Processing and Copying Lesson Overview In this lesson you will learn about Reporting and mass processing functions for master recipes and BOMs Cross-plant copying of master recipes.
Internal
Only
• •
Lesson Objectives After completing this lesson, you will be able to: Use reporting and mass processing functions for master recipes and BOMs Copy master recipes across plants
Business Example You get an overview of the reporting and further functions available for master recipes.
SAP
SAP
Reporting and Mass Processing
Use
Partner
• •
Only
Internal
Use
Partner
Figure 114: Reporting and Mass Processing
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Unit 9: Master Recipes (III)
PLM115
Copying Recipes from Other Plants
Use
Partner
Only
Internal
Figure 115: Copying Recipes from Other Plants
SAP
For the following objects, the reference to the original plant also remains in the new recipe:
Use
The following objects are copied to the new recipe with reference to the target plant.
As of Release 4.6C, the system only issues a warning when a resource of the original recipe does not exist in the plant of the copied recipe. The relevant operation of the recipe is then copied without the resource. The data on the recipe object detail screens are checked. You must change the data if an entry does not exist in the target plant or does not comply with the resource data in the target plant. The system does not check whether the master inspection characteristics in the target plant are identical to those used in the template and whether the characteristics of the copied process instructions have also been released for use in process instructions in the target plant.
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Internal
Primary resource, control recipe destination and process instructions. These objects must already exist in the target plant. Otherwise, copying is terminated.
Partner
Header material of the recipe and factory calendar of relationships.
SAP
When creating a master recipe by copying, you can also use a recipe, routing, or inspection plan belonging to a different plant as a template.
PLM115
Lesson: Reporting, Mass Processing and Copying
The system does not copy production versions, material quantity calculations, and relationships to other recipes. It copies the component assignments to operations and phases maintained in the template. To be able to use them in the new recipe, however, you must create production versions to assign the alternative BOMs of the template to the new recipe.
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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Unit 9: Master Recipes (III)
PLM115
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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PLM115
Lesson: Reporting, Mass Processing and Copying
Exercise 17: Reporting, Mass Processing and Copying Exercise Objectives
Only
Task:
Internal
Business Example
Partner
After completing this exercise, you will be able to: • Use reporting and mass processing functions for master recipes and BOMs
Finally, you get an overview of the reporting and further functions available for master recipes.
Reporting and mass changes of master recipes
Use
1.
a) Recipe list Create a print list for the master recipe T-ICE##.
SAP
2
Recipe group:
T-ICE##
You want component assignments displayed in the list. Program → Execute
(…) → Master Recipes → Reporting < ...> c) Familiarize yourself with the mass changes that are possible for master data. (...) → Master Recipes → Mass Changes → < ...>
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Internal
b) Familiarize yourself with the further reporting functions that are available for production versions, master recipes and BOMs.
Partner
Use
Task list type:
SAP
(…) → Master Recipes → Reporting → Recipe → Recipe List
Unit 9: Master Recipes (III)
PLM115
Solution 17: Reporting, Mass Processing and Copying Task: Reporting and mass changes of master recipes 1.
a) Recipe list
Only
Internal
Create a print list for the master recipe T-ICE##.
Task list type:
2
Recipe group:
T-ICE##
You want component assignments displayed in the list. Program → Execute
(…) → Master Recipes → Reporting < ...> c) Familiarize yourself with the mass changes that are possible for master data.
Use
a)
Partner
(...) → Master Recipes → Mass Changes → < ...> Solution a to c: → Mass changes →
Internal
→ Reporting → → Production Versions
Only
→ Recipe → Recipe list → Recipe Changes → Change Documents → Material List → → Where-Used List →
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SAP
SAP
b) Familiarize yourself with the further reporting functions that are available for production versions, master recipes and BOMs.
Use
Partner
(…) → Master Recipes → Reporting → Recipe → Recipe List
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PLM115
Lesson: Reporting, Mass Processing and Copying
Lesson Summary You should now be able to: • Use reporting and mass processing functions for master recipes and BOMs • Copy master recipes across plants
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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Unit Summary
PLM115
Unit Summary You should now be able to: • Describe the principle of process management • Maintain control recipe destinations and process instructions in the master recipe • Design a simple PI sheet in the master recipe • Use reporting and mass processing functions for master recipes and BOMs • Copy master recipes across plants
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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PLM115
Test Your Knowledge
Partner
Which functions does process management comprise?
2.
Which alternatives are available for process instructions maintenance?? Try to describe the alternatives in key words.
3.
Name some reporting and mass processing functions for master recipes and BOMs.
Use
1.
Internal
Only
Test Your Knowledge
SAP
SAP Only
Internal
Use
Partner
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Test Your Knowledge
PLM115
Answers 1.
Which functions does process management comprise? Answer:
•
2.
Which alternatives are available for process instructions maintenance?? Try to describe the alternatives in key words. Answer: Alternative 1 (All Releases)
– – –
360
Maintenance of all process instructions in XSteps (Execution Steps) in the XStep Editor of the recipe/process order Option of copy of reference of standard XSteps from the Standard XStep Repository Assigning the control recipe destination and maintenance of the generation scope, context and parameters for the XSteps
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Only
Internal
•
Presetting the process instruction types in Customizing Maintenance of the process instructions based on copied process instructions for the phases of the recipe/process order – Assigning the control recipe destinations to the phases – Definition of process instructions to be generated for the control recipe destinations in Customizing. Alternative 2 (as of SAP R/3 ERP and SCM Extension 2.00)
Partner
Use
– –
SAP
SAP
•
Use
Partner
•
Generation and sending of control recipes Automated processing: transferring the control recipes to the process control system Manual processing: Formatting the control recipes in natural language as PI sheets Receiving and processing process messages with actual process data from the process control system or the PI sheet
Internal
Only
• •
PLM115
Test Your Knowledge
3.
Name some reporting and mass processing functions for master recipes and BOMs. Answer: •
Recipe List: Print list for master recipes
•
Recipe Changes:
Only
•
Internal
Change documentation for recipe objects Where-Used list: –
Use in master recipes:
Partner
Resources, process instructions –
Used in BOMs:
SAP Use
• •
– for master recipes – for BOMs BOM explosion BOM comparison
Only
Internal
•
– Recipe: Replace Resources / Process Instructions – BOM: Replace Material Change documents:
Partner
Mass Changes:
SAP
•
Use
Material, document, class
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Unit Summary
PLM115
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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Unit 10 Only
Unit Overview
Partner
This chapter introduces you to the settings in the material master and BOM for the manufacture of co-products.
Use
Unit Objectives After completing this unit, you will be able to:
SAP Use
Unit Contents
Only
Internal
Lesson: Manufacture of Co-Products - Overview .............................. 364 Lesson: Maintaining Material and BOM.......................................... 367 Exercise 18: Maintaining Material and BOM................................ 371
Partner
•
Describe the principle of the manufacture of co-products Maintain material masters and BOMs for the manufacture of co-products Create apportionment structures for the cost apportionment when manufacturing co-products Create a process order for a co-product
SAP
• • •
Internal
Aspects of the Manufacture of Co-Products
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Unit 10: Aspects of the Manufacture of Co-Products
PLM115
Lesson: Manufacture of Co-Products - Overview Lesson Overview This lesson familiarizes you with the principle of the manufacture of co-products.
Lesson Objectives •
Describe the principle of the manufacture of co-products
Business Example
Use
Partner
There are production processes in your enterprise in which a number of different materials are produced at the same time. You want to use the manufacture of co-products to represent these processes.
Internal
Only
After completing this lesson, you will be able to:
Manufacture of Co-Products
SAP
SAP Only
Internal
Use
Partner
Figure 116: Manufacture of Co-Products
The production of several materials that are to be treated as equals in the order, as far as cost calculation and goods receipt are concerned, is called manufacture of co-products.
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Lesson: Manufacture of Co-Products - Overview
In the settlement rule of the order, all co-products involved are defined as settlement receivers. The order costs incurred are distributed to the co-products according to an apportionment structure. Each co-product has its own goods receipt data in the order. Goods receipts take place with movement type 101 Goods receipt for order . Goods receipts for by-products take place with movement type 531 Goods receipt for by-product. Order costs and order settlement do not affect by-products.
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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Unit 10: Aspects of the Manufacture of Co-Products
PLM115
Lesson Summary You should now be able to: • Describe the principle of the manufacture of co-products
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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PLM115
Lesson: Maintaining Material and BOM
Lesson: Maintaining Material and BOM Lesson Overview This lesson familiarizes you with the settings in the material master and BOM for the manufacture of co-products.
Only
Maintain material masters and BOMs for the manufacture of co-products Create apportionment structures for the cost apportionment when manufacturing co-products Create a process order for a co-product
Business Example Your enterprise also produces fertilizer.
SAP
To map the manufacture of co-products onto the system, you must adjust the existing BOM for fertilizer production.
Use
Only
Internal
In particular, you must define an apportionment structure for cost apportionment in the process order.
Partner
You must also make the corresponding changes to the material masters of the co-products.
SAP
During the production process, the material "sulphuric acid" is produced along with the main product. Sulphuric acid is to be considered an equal "co-product".
Use
•
• •
Internal
After completing this lesson, you will be able to:
Partner
Lesson Objectives
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Unit 10: Aspects of the Manufacture of Co-Products
PLM115
Material Master
Use
Partner
Only
Internal
The Co-product indicator must be set in the material master of a material that is to be manufactured as a co-product.
Use Internal
When you create a process order, the system uses this data to automatically generate a settlement rule. This settlement rule is then used to distribute the total costs incurred to the co-products. A source structure is used to distribute the equivalences in the apportionment structure according to cost element groups. How the costs are apportioned to the individual co-products can then differ according to the various cost element groups involved. You define source structures in Customizing.
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Only
In the material master record, you define one or more apportionment structures. An apportionment structure specifies how the order costs are to be distributed to the co-products manufactured in a specific production process. You can maintain equivalence numbers for each apportionment structure and assign the apportionment structure to a production version.
Partner
When manufacturing co-products, the entire costs incurred for the process order are collected at order header level and distributed to the individual co-products using equivalence numbers.
SAP
SAP
Figure 117: Material Master
PLM115
Lesson: Maintaining Material and BOM
BOM
Partner
Only
Internal
Figure 118: BOM
SAP Use
The manufacture of co-products can also be mappped onto the system by using the material type PROC Process material. A process material is specifically used to represent the manufacture of co-products. A process material is not a physically existing material but rather it represents a manufacturing process.
Internal
The Co-product indicator must also be set for BOM items to which co-products have been assigned.
If you use a process material as the BOM header, all co-products of the production process are defined as BOM items with the Co-product indicator.
Only
There is no quantity or value update for a process material. This takes place at co-product level. A process order can either be created for a co-product or for a process material.
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Partner
The Co-product indicator must be set in the material master of the co-products.
SAP
The following prerequisites must be met for the manufacture of co-products:
Use
To map the manufacture of co-products onto the system, you assign a co-product as the leading material to the BOM header. All other co-products appear as BOM items.
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Use
Partner
Only
Internal
Unit 10: Aspects of the Manufacture of Co-Products
SAP
SAP Only
Internal
Use
Partner
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PLM115
Lesson: Maintaining Material and BOM
Exercise 18: Maintaining Material and BOM Exercise Objectives
Only
Business Example During the production process, the material "sulfuric acid" is produced along with the main product. Sulphuric acid is to be considered an equal "co-product". To map the manufacture of co-products onto the system, you must adjust the existing BOM for fertilizer production.
SAP
Task 1:
SAP
In particular, you must define an apportionment structure for cost apportionment in the process order.
Use
Partner
Your enterprise also produces fertilizer.
Internal
After completing this exercise, you will be able to: • Maintain material masters and BOMs for the manufacture of co-products • Create apportionment structures for the cost apportionment when manufacturing co-products • Create a process order for a co-product
1.
Internal
2.
Familiarize yourself with the data in master recipe 1 of the recipe group T-RC1## Recipe group for fertilizer production. Operation overview Familiarize yourself with the operations, phases and resources assigned.
3.
Recipe header data
Only
Display the recipe header data. Which material is assigned to the recipe as a product? ________________________ 4.
Material list Familiarize yourself with the material components that are assigned to the recipe. Which materials are assigned? Continued on next page
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Use
Overview of master recipe T-RC1##
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Unit 10: Aspects of the Manufacture of Co-Products
PLM115
________________________ ________________________ ________________________
Task 2: Material master: Co-Product indicator
Only
Set the Co-Product indicator for your materials T-FF1## Fertilizer and T-FF3## Sulfuric acid in the material master or check whether the indicator has been set. View: MRP 2
Task 3: BOM 1.
Enter the material T-FF3## in the master recipe T-RC1## as a co-product in the BOM of the “leading“ product T-FF1##.
SAP
ICt
Component
Quantity
Un
0040
L
T-FF3##
7-
L
Partner
Use
Item
SAP
Maintain the following new BOM item:
Set the Co-Product indicator for the new BOM item T-FF3##. Adjust the base quantity in the BOM header. Save your recipe.
Task 4: Material master: apportionment structure In the material master record for the leading product T-FF1##, create an apportionment structure for distributing the process order costs to the co-products T-FF1## and T-FF3## for the fertilizer production process. View: MRP 2 Plant: 1100 Continued on next page
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Internal
In the material list, assign the co-product T-FF3## to phase 330.
1.
Use
Partner
Plant: 1100
Internal
1.
PLM115
Lesson: Maintaining Material and BOM
Choose Joint production The Cost Apportionment to Co-Products: Apportionment Structures screen appears. Enter a number and a description for the apportionment structure. In addition, assign the source structure PI so you can directly distribute the production costs to different cost element groups.
Only
Structure
0001
T-FF1## & T-FF3##
PI
You can now enter equivalence numbers to define how you want to distribute the order costs to the co-products.
Maintain the following equivalence numbers:
Choose Equivalence Numbers
Internal
EqNo
1 "Material costs"
T-FF1##
10
1 "Material costs"
T-FF3##
1
2 "Production costs"
T-FF1##
5
2 "Production costs"
T-FF3##
3
3 "Other costs"
T-FF1##
2
3 "Other costs"
T-FF3##
1
Only
Co-product
Partner
Assignment
SAP
Use
Since you assigned a source structure, you can distribute the costs to cost element groups. You can enter a cost element group defined in the source structure in the Assignments field.
Save your material master record.
Task 5: Material master: assigning an apportionment structure to a production version 1.
In the material master record for the product T-FF1##, assign your apportionment structure 0001 to production version 0001. Continued on next page
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Description
SAP
No.
Internal
Apportionment structure
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Unit 10: Aspects of the Manufacture of Co-Products
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View: MRP 4 Plant: 1100 Choose ProdVersions Choose Details Apportionment structure: 0001
Only
Optional exercises: 1.
Source structure in Customizing
Partner
In Customizing, display the source structure PI with which the production costs are directly distributed to the different cost element groups. Write down the following:
Use
Assignment
Cost element group
Material costs
SAP
SAP
Production costs Other costs Cost element groups in Controlling
Use
Only
Internal
Cost element:
Partner
In Controlling, display the above cost element groups and list three cost elements for each cost element group: Cost element group:
Internal
Task 6:
Continued on next page
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PLM115
Lesson: Maintaining Material and BOM
Task 7: Creating process orders for the co-products Create a process order (order type PI01) for the leading product T-FF1## in production plant 1100. Total quantity:
(for example) 1000 L
Basic dates: Finish
(for example) today + 1 week
On the Operation Overview and the Material List screens, check whether the data from your master recipe has been copied correctly. Note the two order items for the co-products in the material list.
Create a process order (order type PI01) for the co-product T-FF3##. Total quantity:
(for example) 70 L
Basic dates: Finish
(for example) today + 1 week
In the order header, the co-product T-FF3## is replaced by the leading BOM material T-FF1##.
Use
Only
Internal
Partner
The quantity to be produced for the leading BOM material T-FF1 is calculated from the quantity desired for your co-product T-FF3##.
SAP
SAP
2.
Use
Partner
In addition, check in the settlement rule whether your apportionment structure for the co-products was adopted.
Internal
Only
1.
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Unit 10: Aspects of the Manufacture of Co-Products
PLM115
Solution 18: Maintaining Material and BOM Task 1: Overview of master recipe T-RC1## 1.
Familiarize yourself with the data in master recipe 1 of the recipe group T-RC1## Recipe group for fertilizer production. (…) → Master Data → Production Versions
Internal
Only
a)
Plant: 1100 Group Counter: T-RC1##
Partner
Select the production version Choose Recipe 2.
Operation overview
Use
Familiarize yourself with the operations, phases and resources assigned. a)
SAP
Recipe header data
SAP
3.
Operation overview
Display the recipe header data. Which material is assigned to the recipe as a product?
Use
a)
Partner
________________________ Recipe header data Recipe header tab Choose Material Assignments T-FF1##, Fertilizer, fluid, form A 4.
Material list Familiarize yourself with the material components that are assigned to the recipe. Which materials are assigned? ________________________ ________________________ Continued on next page
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Internal
Which material is assigned to the recipe as a product?
PLM115
Lesson: Maintaining Material and BOM
________________________ a)
Recipes tab Materials icon Which materials are assigned? T-RF1## T-RF3##
Only
Task 2:
Partner
Material master: Co-Product indicator 1.
Set the Co-Product indicator for your materials T-FF1## Fertilizer and T-FF3## Sulfuric acid in the material master or check whether the indicator has been set.
Use
View: MRP 2 Plant: 1100 (…) → Master Data → Material Master → Material → Change → Immediately
SAP
SAP
a)
View: MRP 2 Plant: 1100
Use
Task 3: Enter the material T-FF3## in the master recipe T-RC1## as a co-product in the BOM of the “leading“ product T-FF1##. Maintain the following new BOM item: Item
ICt
Component
Quantity
Un
0040
L
T-FF3##
7-
L
Set the Co-Product indicator for the new BOM item T-FF3##. Adjust the base quantity in the BOM header. Continued on next page
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Internal
BOM
Partner
X Co-product
1.
Internal
T-RF2##
Unit 10: Aspects of the Manufacture of Co-Products
PLM115
In the material list, assign the co-product T-FF3## to phase 330. Save your recipe. a)
(…) → Master Data → Production Versions Plant: 1100 Group Counter: T-RC1## Choose Recipe
Only
Internal
Materials tab
Partner
Choose BOM. Item
ICt
Component
Quantity
Un
0040
L
T-FF3##
7-
L
Use
Set the Co-Product indicator for the new BOM item T-FF3##. Choose the Item icon for item T-FF3##. X Co-product
SAP
SAP
Change the base quantity in the BOM header to 1000 L. Choose the Header icon Base quantity: 1000 L
Use
Choose Back (F3) Choose the Create assignment icon for component T-FF3##.
Task 4: Material master: apportionment structure 1.
In the material master record for the leading product T-FF1##, create an apportionment structure for distributing the process order costs to the co-products T-FF1## and T-FF3## for the fertilizer production process. View: MRP 2 Plant: 1100 Continued on next page
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Internal
The Materials tab for your recipe appears.
Partner
Then assign the co-product T-FF3## to phase 330 in the material list.
PLM115
Lesson: Maintaining Material and BOM
Choose Joint production The Cost Apportionment to Co-Products: Apportionment Structures screen appears. Enter a number and a description for the apportionment structure. In addition, assign the source structure PI so you can directly distribute the production costs to different cost element groups.
Only
Structure
0001
T-FF1## & T-FF3##
PI
You can now enter equivalence numbers to define how you want to distribute the order costs to the co-products.
Maintain the following equivalence numbers:
Choose Equivalence Numbers
Internal
EqNo
1 "Material costs"
T-FF1##
10
1 "Material costs"
T-FF3##
1
2 "Production costs"
T-FF1##
5
2 "Production costs"
T-FF3##
3
3 "Other costs"
T-FF1##
2
3 "Other costs"
T-FF3##
1
Only
Co-product
Partner
Assignment
SAP
Use
Since you assigned a source structure, you can distribute the costs to cost element groups. You can enter a cost element group defined in the source structure in the Assignments field.
Continued on next page
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Use
Partner
Description
SAP
No.
Internal
Apportionment structure
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Unit 10: Aspects of the Manufacture of Co-Products
PLM115
Save your material master record. a)
(…) → Master Data → Material Master → Material → Change → Immediately Material: T-FF1## View: MRP 2 Plant: 1100
Only
The Cost Apportionment to Co-Products: Apportionment Structures screen appears.
Task 5: Material master: assigning an apportionment structure to a production version 1.
In the material master record for the product T-FF1##, assign your apportionment structure 0001 to production version 0001.
SAP
SAP
View: MRP 4 Plant: 1100 Choose ProdVersions
Use
Apportionment structure: 0001
Internal
(…) → Master Data → Material Master → Material → Change → Immediately View: MRP 4
Only
Plant: 1100 Choose ProdVersions Choose Details Apportionment structure: 0001
Continued on next page
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Choose Details a)
Use
Partner
See exercise
Internal
Choose Joint production
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PLM115
Lesson: Maintaining Material and BOM
Task 6: Optional exercises: 1.
Source structure in Customizing In Customizing, display the source structure PI with which the production costs are directly distributed to the different cost element groups.
Assignment
Internal
Only
Write down the following: Cost element group
Material costs Production costs
Partner
Other costs Cost element groups in Controlling
Cost element:
SAP
SAP
Cost element group:
Use
In Controlling, display the above cost element groups and list three cost elements for each cost element group:
Only
Internal
Use
Partner
Continued on next page
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Unit 10: Aspects of the Manufacture of Co-Products
Cost element group:
Cost element:
Select source structure PI.
(Controlling area 1000)
Internal
Only
Customizing: → Controlling → Product Cost Controlling → Product Cost Planning → Selected Functions in Material Costing → Costing in Joint Production → Define Source Structure
Partner
a)
PLM115
Double-click the Assignments folder.
Cost element group
Material costs
CO – PC – MAT
Production costs
CO – PC – PROD
Other costs
CO – PC – MISC
SAP
Assignment
Use
SAP
Double-click the Source folder for each assignment.
Cost element groups in Controlling
Use Internal
Cost element group:
Cost element:
CO – PC – MAT
400000 Raw material 404000 Replacement parts
Partner
SAP Easy Access menu → Accounting → Controlling → Cost Element Accounting → Master Data → Cost Element Group → Display
405000 Packaging
Only
CO – PC – PROD
620000 Machine costs 629600 Staging 625000 Setup
CO – PC – MISC
655300 OH management 655400 OH sales 416200 Electricity consumption Continued on next page
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Lesson: Maintaining Material and BOM
Task 7: Creating process orders for the co-products Create a process order (order type PI01) for the leading product T-FF1## in production plant 1100. Total quantity:
(for example) 1000 L
Basic dates: Finish
(for example) today + 1 week
On the Operation Overview and the Material List screens, check whether the data from your master recipe has been copied correctly. Note the two order items for the co-products in the material list.
a)
Create a process order (order type PI01) for the co-product T-FF3##. Total quantity:
(for example) 70 L
Basic dates: Finish
(for example) today + 1 week
SAP
SAP
2.
(…) → Logistics → Production - Process → Process Order → Process Order → Create → With Material
Use Internal
The quantity to be produced for the leading BOM material T-FF1 is calculated from the quantity desired for your co-product T-FF3##. In the order header:
Partner
In the order header, the co-product T-FF3## is replaced by the leading BOM material T-FF1##.
a)
Use
Partner
In addition, check in the settlement rule whether your apportionment structure for the co-products was adopted.
Internal
Only
1.
Header → Settlement Rule
Only
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Unit 10: Aspects of the Manufacture of Co-Products
PLM115
Lesson Summary You should now be able to: • Maintain material masters and BOMs for the manufacture of co-products • Create apportionment structures for the cost apportionment when manufacturing co-products • Create a process order for a co-product
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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Unit Summary
Unit Summary You should now be able to: • Describe the principle of the manufacture of co-products • Maintain material masters and BOMs for the manufacture of co-products • Create apportionment structures for the cost apportionment when manufacturing co-products • Create a process order for a co-product
Use
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Only
Internal
SAP
SAP Only
Internal
Use
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Unit Summary
PLM115
Use
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Only
Internal
SAP
SAP Only
Internal
Use
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PLM115
Test Your Knowledge
Which movement type is used for goods receipts for the manufacture of co-products, and which is used for by-products?
2.
Which prerequisites for the manufacture of co-products have to be taken into account in the master data maintenance for material and BOM?
Use
Partner
1.
Internal
Only
Test Your Knowledge
SAP
SAP Only
Internal
Use
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Test Your Knowledge
PLM115
Answers 1.
Which movement type is used for goods receipts for the manufacture of co-products, and which is used for by-products? Answer:
Only
2.
Co-products: movement type 101 Goods receipt for order By-products: movement type 531 Goods receipt for by-product
Which prerequisites for the manufacture of co-products have to be taken into account in the master data maintenance for material and BOM?
• •
SAP
SAP
•
The Co-product indicator must be set in the material master of the co-products. The Co-product indicator must also be set for BOM items to which co-products have been assigned. You define an apportionment structure in the material master for the cost apportionment for the manufacture of co-products.
Use
Partner
Answer:
Internal
• •
Only
Internal
Use
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Unit 11 Only
Unit Overview
Partner
This chapter introduces you to the fundamental maintenance activities in the material master and master recipe for quality inspections during production.
Use
Unit Objectives After completing this unit, you will be able to:
SAP
Describe the integration with quality management Maintain the material master and master recipe with regard to in-process quality inspection
Use
Only
Internal
Lesson: Integration with Quality Management .................................. 390 Lesson: In-Process Quality Inspection........................................... 394 Exercise 19: In-Process Quality Inspection ................................. 399
Partner
Unit Contents
SAP
• •
Internal
Aspects of Quality Inspection During Production
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Unit 11: Aspects of Quality Inspection During Production
PLM115
Lesson: Integration with Quality Management Lesson Overview This lesson familiarizes you with the integration of quality management and the term 'inspection lot'.
Lesson Objectives
Only
•
Describe the integration with quality management
Partner
Business Example You need to check the quality of your products in parallel to process order processing for part of your production.
Internal
After completing this lesson, you will be able to:
Use
Integration with Quality Management
SAP
SAP Only
Internal
Use
Partner
Figure 119: Integration with Quality Management
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PLM115
Lesson: Integration with Quality Management
Between the production plant and the laboratory or the quality assurance system, information on product quality and analysis values can be exchanged. This happens when the ECC Quality Management System is used, with or without linking to external LIMS (laboratory information systems). You define the specifications of a quality inspection in the inspection characteristics of an inspection lot in ECC QM. During inspection results recording, the results of the quality inspection are assigned to the inspection characteristics of the inspection lot.
Only Partner SAP
SAP
ECC QM can be linked to an LIMS using the QM-IDI interface. In this case, inspection specifications are transferred from ECC QM to the LIMS, which in turn sends the inspection results back to ECC QM.
Use
You can also check the product quality before a goods receipt after production. In this case, an inspection lot is created from an inspection plan maintained in ECC QM.
Internal
There is a direct link between ECC Process Manufacturing and ECC Quality Management. The quality of materials produced can be checked in an in-process inspection taking place in parallel to the production process. In this case, the inspection lot is created with reference to the corresponding process order. The inspection characteristics are created in the operations and phases of the master recipe the process order is based on and are then transferred to the inspection lot. Inspection results recording takes place when the process order is carried out. If the product is to be handled in batches, inspection results can be used for batch specification by automatically copying them to the class characteristics of the batch produced.
Only
Internal
Use
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Unit 11: Aspects of Quality Inspection During Production
PLM115
Inspection Lot
Use
Partner
Only
Internal
The functions of quality inspection of the SAP ECC System are fully integrated with the entire logistics process. They affect all business activities (such as product planning, production, procurement and sales).
Use Internal
In other applications, such as a goods receipt, the inspection lot is created on the basis of an inspection plan maintained in ECC QM. Inspection plans are master data of ECC QM.
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Only
In-process inspection takes place parallel to the production process. The inspection lot is either created manually or automatically from within the process order when the order is released. The inspection characteristics are maintained for the operations or phases of the master recipe on which the process order is based. They are then transferred to the inspection lot. The inspection results are recorded for the inspection characteristics of the inspection lot while the process order is carried out.
Partner
A quality inspection can only be carried out if an inspection lot is created. Inspection lots are fully integrated in the supply chain, such as the neighboring ECC tasks of goods receipt, goods issue and process order. They document the entire inspection process, from inspection specifications to inspection results recording, and to the usage decision. They can be created automatically or manually from different sources of the corresponding application.
SAP
SAP
Figure 120: Inspection Lot
PLM115
Lesson: Integration with Quality Management
Lesson Summary You should now be able to: • Describe the integration with quality management
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
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Unit 11: Aspects of Quality Inspection During Production
PLM115
Lesson: In-Process Quality Inspection Lesson Overview This lesson familiarizes you with the data maintenance for representing an in-process quality inspection.
Only
Maintain the material master and master recipe with regard to in-process quality inspection
You need to check the quality of your products in parallel to process order processing for part of your production. You want to update the relevant batch master records with some of the inspection results.
SAP
SAP
You make the necessary settings in the materials and master recipes affected.
Use
Business Example
•
Internal
After completing this lesson, you will be able to:
Partner
Lesson Objectives
Only
Internal
Use
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PLM115
Lesson: In-Process Quality Inspection
In-Process Inspection: Inspection Lot
Use
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Only
Internal
SAP Use Internal
Later, you can also add unplanned inspection characteristics from within the process order.
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Only
You can either create the inspection lot manually or the system creates it automatically when you release the process order. For the system to be able to do so, you must activate the inspection type Inspection during production in the material master of the material to be checked. The inspection characteristics for the operations or phases of the master recipe are then transferred to the corresponding inspection operations of the inspection lot.
Partner
In an in-process quality inspection, the inspection lot is created on the basis of the underlying master recipe. In the master recipe, you maintain inspection specifications in the form of inspection characteristics for the corresponding operations or phases. You must define further QM data at the recipe's header level and operation or phase level.
SAP
Figure 121: In-Process Inspection: Inspection Lot
Unit 11: Aspects of Quality Inspection During Production
PLM115
Inspection Points, Partial Lots, and Batches
Use
Partner
Only
Internal
Figure 122: Inspection Points, Partial Lots, and Batches
SAP Use Internal
Partial lots describe a certain production quantity during production. This quantity is processed in several operations or phases. For each operation or phase, you can perform an inspection with inspection points for different inspection characteristics and assign the results to the partial lot. A new partial lot is created when the first inspection point of this partial lot is processed.
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Inspection results recording is performed for the inspection characteristics of the inspection lot with exactly one inspection lot being created for each process order. If partial quantities with different specifications are produced in a process order, you can assign inspection points to a corresponding partial lot to record inspection results. You can create several partial lots.
Partner
If you set the Inspection points indicator on the QM Data recipe header detail screen, all in-process inspection results recordings are carried out with relation to inspection points. Unlike inspection without inspection points, you can record inspection results for the inspection characteristics of the same inspection operation several times. The intervals between the inspection points can be time-related (that is, at certain points in time), quantity-related (that is, after a certain quantity has been produced), or freely defined.
SAP
The graphic shows the general relationship between inspection points, partial lots and batches.
PLM115
Lesson: In-Process Quality Inspection
An example where partial lots are used is the manufacture of co-products, that is, the production of several materials in one process order. Each co-product can be represented by a partial lot. If the finished product is managed in batches, you can assign partial lots to individual batches. Selected inspection results can automatically be copied to the class characteristics of the batch for batch specification.
Specification of Batches Produced
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Master inspection characteristics are master data maintained in ECC QM. They facilitate the maintenance of routine inspections and enable a linking to the class characteristics of batches. Due to this link, quality inspection results can automatically be copied from the inspection characteristics to the corresponding class characteristics of the batch produced. If you choose inspection with inspection points, inspection points are assigned to a corresponding partial lot to record inspection results. You can assign several partial lots to an inspection lot. A partial lot describes a discrete production quantity that can
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In an in-process inspection, inspection specifications are defined using inspection characteristics for the operations and phases of the master recipe, on which the process order or inspection lot are based. You can either create inspection characteristics in the master recipe or refer to already existing master inspection characteristics.
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Figure 123: Specification of Batches Produced
Unit 11: Aspects of Quality Inspection During Production
PLM115
be assigned to a batch. Once a usage decision for this inspection point has been made, the inspection results of an inspection point are transferred to the class characteristics of the batch linked to the master inspection characteristics. If you want to carry out an inspection without inspection points, inspection results are recorded for the entire inspection lot. You can assign the production quantity to a batch. Once a usage decision for the entire inspection lot has been made, the inspection results are transferred to the class characteristics of the batch linked to the master inspection characteristics.
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PLM115
Lesson: In-Process Quality Inspection
Exercise 19: In-Process Quality Inspection Exercise Objectives After completing this exercise, you will be able to: • Maintain the material master and master recipe with regard to in-process quality inspection
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You need to check the quality of your products in parallel to process order processing for part of your production.
Partner
You want to update the relevant batch master records with some of the inspection results. You make the necessary settings in the materials and master recipes affected.
Use
Task 1:
SAP
Use
Quality Management view
Inspection type: ___________________________________
Partner
SAP
You must activate the inspection type In-process inspection of production order in the material master so that an in-process quality inspection can be carried out for process orders for the production of your material T-HTB2## Cetepharm-N tablet. First, check whether this setting has been made.
Internal
Material master: inspection type In-process inspection of production order 1.
Internal
Business Example
Plant: 1100 Choose Insp. setup Activation indicator set?: yes/no
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Task 2: Master inspection characteristics 1.
During the tablet production, the water contents and active ingredient contents are to be inspected during the production process. Master inspection characteristics have been created for this in master data maintenance of Quality Management. Display the following master inspection characteristics for plant 1100. What are the descriptions for each characteristic? Continued on next page
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Unit 11: Aspects of Quality Inspection During Production
PLM115
Logistics → Quality Management → Quality Planning → Basic Data → Inspection Characteristic → Display Master insp. charac.
Description
N-200 N-300
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Master insp. charac.
Class char.
Partner
1.
To describe the production of product T-HTB2## Cetepharm N tablet, production version 0001 was created with reference to recipe 1 of recipe group T-TAB##. Control key To which phase is control key PI02 assigned in the operation overview?
Use
Which indicator is set for control key PI02 with regard to a quality inspection? _________________________________
Internal
3.
Inspection characteristics assigned Which inspection characteristics are to be checked for phase 0320?
Master insp. charac.
4.
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Choose the Inspection characteristic icon for phase 0320. Description
Process instruction QMJUMPPH In the process instruction overview, navigate to phase 0320. Continued on next page
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Phase number: ___________________
SAP
2.
Master Recipe
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Task 3:
SAP
N-300
Internal
The batch we will produce is to be specified according to the inspection results for the active ingredient content. To which class or batch characteristic does the data for master inspection characteristic N-300 refer?
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Lesson: In-Process Quality Inspection
The process instruction QMJUMPPH Jump to QM results recording, phase of type 5 Inspection results request enables you to directly navigate to the right inspection results view of the inspection lot currently assigned to the process order from a PI sheet.
Task 4: Inspection results recording for phase 0320
Only
1.
Creating a process order for material T-HTB2##
Total quantity:
100 000 pieces
Basic dates: Start
(for example) today + 1 week
Use
Partner
Create a process order of the process order type PI04 for the material T-HTB2### in plant 1100.
The master recipe T-TAB## is copied along with the material list.
SAP
Save your order and write down the process order number.
Use
Release the process order and generate the control recipes Release your order.
In addition, a batch number is assigned for your product T-HTB2## (see Goods receipt tab in the order header). Write down the batch number. Batch number: _________________________ Create the control recipes for the order. Then save your order. 3.
Sending the control recipe and maintaining the PI sheet Select the control recipes for your process order in the control recipe monitor. Continued on next page
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Note that when you release the order, an inspection lot is automatically created with reference to the order (see Assignment tab in the order header).
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Process order number: _________________________
SAP
In the operation overview and in the material list, check whether the data in master recipe T-TAB## has been copied correctly.
2.
Internal
In the following exercise, you will perform an in-process quality inspection from a PI sheet (based on the master data shown in the previous exercises).
Unit 11: Aspects of Quality Inspection During Production
PLM115
Send the control recipe for control recipe destination QM. Search for the corresponding PI sheet and maintain it. Enter your signature for phase 310 to confirm the start of PI sheet maintenance and the preparation of the QM inspection. Use your user to sign and the password to confirm the signature. Enter another signature for phase 320 to confirm that you have identified the physical sample.
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Recording inspection results Choose the Insp.results recording button in phase 0320.
On the Record Results: Characteristic Overview, enter the inspection results in the Result column for the inspection characteristics Water content and active ingredient content (for example, Water content: 1.5 %, Active ingredient content: 98 %). Choose Enter to confirm your entries and save.
SAP
SAP
The system takes you back to the PI sheet. If there is enough time, maintain the remaining steps in the PI sheet. Then exit your PI sheet.
Use
Displaying a batch with inspection results Display the order batch for material T-HTB2##.
Internal
Go to the classification data for the batch. Check whether the value you entered for the active ingredient content in inspection results recording was copied to the batch master record.
Partner
5.
Use
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Enter any number to identify your inspection point and confirm by choosing Enter.
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4.
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Lesson: In-Process Quality Inspection
Solution 19: In-Process Quality Inspection Task 1: Material master: inspection type In-process inspection of production order You must activate the inspection type In-process inspection of production order in the material master so that an in-process quality inspection can be carried out for process orders for the production of your material T-HTB2## Cetepharm-N tablet. First, check whether this setting has been made. Quality Management view Plant: 1100 Inspection type: ___________________________________ Activation indicator set?: yes/no a)
Material master: inspection type In-process inspection of production order
SAP
SAP
(…) → Material Master → Material → Display → Display Current Material: T-HTB2## Quality Management view
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Plant: 1100 Choose Insp. setup Inspection type: 03 = In-process insp. for production order
Task 2: Master inspection characteristics During the tablet production, the water contents and active ingredient contents are to be inspected during the production process. Master inspection characteristics have been created for this in master data maintenance of Quality Management. Display the following master inspection characteristics for plant 1100. What are the descriptions for each characteristic?
Continued on next page
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Activation indicator set: yes
1.
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Choose Insp. setup
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1.
Unit 11: Aspects of Quality Inspection During Production
PLM115
Logistics → Quality Management → Quality Planning → Basic Data → Inspection Characteristic → Display Master insp. charac.
Description
N-200 N-300
Only
Master insp. charac.
Class char.
Master insp. charac.
Description
N-200
Water content
N-300
Active ingredient content
Master insp. charac.
Class char.
N-300
N-006
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Use
Logistics → Quality Management → Quality Planning → Basic Data → Inspection Characteristic → Display
SAP
SAP
a)
Master Recipe To describe the production of product T-HTB2## Cetepharm N tablet, production version 0001 was created with reference to recipe 1 of recipe group T-TAB##. a)
(…) → Production Versions Selecting the production version for recipe T-HTB2## Choose Recipe (for the selected production version)
2.
Control key To which phase is control key PI02 assigned in the operation overview? Continued on next page
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Task 3: 1.
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N-300
Internal
The batch we will produce is to be specified according to the inspection results for the active ingredient content. To which class or batch characteristic does the data for master inspection characteristic N-300 refer?
PLM115
Lesson: In-Process Quality Inspection
Phase number: ___________________ Which indicator is set for control key PI02 with regard to a quality inspection? _________________________________ a)
Phase number: 0320 Control key: PI02 F4 for control key PI02
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Internal
Choose Detail info for control key PI02 Insp.char. required indicator 3.
Inspection characteristics assigned
Partner
Which inspection characteristics are to be checked for phase 0320? Choose the Inspection characteristic icon for phase 0320.
SAP Use
Master insp. charac.
Description
N-200
Water content
N-300
Active ingredient content
Process instruction QMJUMPPH In the process instruction overview, navigate to phase 0320. The process instruction QMJUMPPH Jump to QM results recording, phase of type 5 Inspection results request enables you to directly navigate to the right inspection results view of the inspection lot currently assigned to the process order from a PI sheet. a)
Process instruction QMJUMPPH
Continued on next page
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Choose the Inspection characteristic icon for phase 0320.
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4.
Description
SAP
a)
Use
Master insp. charac.
Unit 11: Aspects of Quality Inspection During Production
PLM115
Task 4: Inspection results recording for phase 0320 In the following exercise, you will perform an in-process quality inspection from a PI sheet (based on the master data shown in the previous exercises). 1.
Creating a process order for material T-HTB2##
Basic dates: Start
(for example) today + 1 week
a)
In the operation overview and in the material list, check whether the data in master recipe T-TAB## has been copied correctly. Save your order and write down the process order number. Process order number: _________________________
2.
Logistics → Production - Process → Process Order → Process Order → Create → With Material
Release the process order and generate the control recipes
Use
Note that when you release the order, an inspection lot is automatically created with reference to the order (see Assignment tab in the order header).
Internal
In addition, a batch number is assigned for your product T-HTB2## (see Goods receipt tab in the order header). Write down the batch number.
Partner
Release your order.
SAP
The master recipe T-TAB## is copied along with the material list.
Use
Partner
100 000 pieces
SAP
Total quantity:
Internal
Only
Create a process order of the process order type PI04 for the material T-HTB2### in plant 1100.
Batch number: _________________________
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Create the control recipes for the order. Then save your order. a)
(…) → Process Order → Change Choose the Release icon Choose the Generate control recipe icon
3.
Sending the control recipe and maintaining the PI sheet Continued on next page
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Lesson: In-Process Quality Inspection
Select the control recipes for your process order in the control recipe monitor. Send the control recipe for control recipe destination QM. Search for the corresponding PI sheet and maintain it. Enter your signature for phase 310 to confirm the start of PI sheet maintenance and the preparation of the QM inspection. Use your user to sign and the password to confirm the signature.
Only
a)
(…) → Process Management → Control Recipe → Control Recipe Monitor (…) → Process Management → PI Sheet → Find
Recording inspection results Choose the Insp.results recording button in phase 0320. Enter any number to identify your inspection point and confirm by choosing Enter.
SAP
Choose Enter to confirm your entries and save.
Use
Partner
The system takes you back to the PI sheet. If there is enough time, maintain the remaining steps in the PI sheet.
5.
Recording inspection results
Displaying a batch with inspection results
Only
Internal
Then exit your PI sheet. a)
Display the order batch for material T-HTB2##. Go to the classification data for the batch. Check whether the value you entered for the active ingredient content in inspection results recording was copied to the batch master record. a)
(…) → Material Master → Batch → Display Classification tab
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On the Record Results: Characteristic Overview, enter the inspection results in the Result column for the inspection characteristics Water content and active ingredient content (for example, Water content: 1.5 %, Active ingredient content: 98 %).
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4.
Internal
Enter another signature for phase 320 to confirm that you have identified the physical sample.
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Lesson Summary You should now be able to: • Maintain the material master and master recipe with regard to in-process quality inspection
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Unit Summary
Unit Summary You should now be able to: • Describe the integration with quality management • Maintain the material master and master recipe with regard to in-process quality inspection
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Unit Summary
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Test Your Knowledge
Test Your Knowledge 1.
How and where are the inspection specifications defined in an in-process quality inspection?
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Test Your Knowledge
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Answers 1.
How and where are the inspection specifications defined in an in-process quality inspection? Answer: The inspection specifications are defined using inspection characteristics for the operations and phases of the master recipe, on which the process order or inspection lot are based.
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Unit 12 Only
Unit Overview
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This chapter introduces you to fundamental aspects of engineering change management and to mapping the approval procedure for master recipes.
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Unit Objectives After completing this unit, you will be able to:
SAP
Unit Contents
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Lesson: Engineering Change Management - Overview ....................... 414 Lesson: Changes with a Change Master Record............................... 418 Exercise 20: Changes with a Change Master Record..................... 421 Lesson: Recipe Approval .......................................................... 429 Exercise 21: Recipe Approval ................................................ 439
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Use
Describe the principle of using the engineering change management Make changes using change master records Create and process engineering change requests / engineering change orders Carry out an approval procedure for master recipes
SAP
• • • •
Internal
Engineering Change Management, Recipe Approval
Unit 12: Engineering Change Management, Recipe Approval
PLM115
Lesson: Engineering Change Management - Overview Lesson Overview This lesson gives you an overview of how to use the engineering change management.
Lesson Objectives •
Internal
Only
After completing this lesson, you will be able to: Describe the principle of using the engineering change management
Business Example
Partner
You use the engineering change management to plan and document changes.
Use
Engineering Change Management
SAP
SAP Only
Internal
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Figure 124: Engineering Change Management
Engineering change management (ECH) is a central, integrated part of product data management (PDM) within the standard SAP System.
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Lesson: Engineering Change Management - Overview
Why Use Engineering Change Management for Changes?
SAP
A valid-from date for the change master record (or the engineering change request/engineering change order) is used to make changes valid on a predefined date. This enables long-term planning.
Use
You can use engineering change managment to group changes made 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. You can create general documentation for all changes made as well as special documentation for each specific object change. You can use engineering change management to fulfill your legal obligations to document changes.
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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 and production control).
Partner
You can use engineering change management to store SAP objects (for example, BOMs or routings) more than once. This means that the objects can be stored in all relevant change statuses.
SAP
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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Figure 125: Why Use Engineering Change Management for Changes?
Unit 12: Engineering Change Management, Recipe Approval
PLM115
Changes With and Without History
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SAP
Change with history These are changes that must be documented because they take place during production, for example. Both the status before and after the change is saved. The system also generates change documents. For some objects, these change documents differ from those generated for changes without history. Engineering change management in the SAP System allows for complete documentation of changes. Some of these changes may be needed, for example, for product liability purposes.
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Change without history These are changes that do not have to be documented because they take place during the development stage of the product, for example. The status of the object before the change is not saved. You can only find out about the status of the object before the change by using change documents.
Partner
Use
You can make object changes (for example, BOM and master recipe changes) in the SAP System either with or without history. The system can generate change documents even for changes without history.
SAP
Figure 126: Changes With and Without History
PLM115
Lesson: Engineering Change Management - Overview
Lesson Summary You should now be able to: • Describe the principle of using the engineering change management
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Unit 12: Engineering Change Management, Recipe Approval
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Lesson: Changes with a Change Master Record Lesson Overview This lesson familiarizes you with making changes using change master records.
Lesson Objectives •
Make changes using change master records
Business Example
Partner
For reasons of product safety, some master data changes in your enterprise have to be made with reference to change master records.
Use
Change Master Record (Change Number)
Internal
Only
After completing this lesson, you will be able to:
SAP
SAP
Internal
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Figure 127: Change Master Record (Change Number)
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Lesson: Changes with a Change Master Record
Change master records (synonymous with change numbers) are used to plan changes in advance and combine related changes to different objects, such as master recipes, materials, and bills of material. They are created within engineering change management and can contain such information as:
•
Detailed documentation of planned changes The date from which the changes are to be valid The types of objects and, if required, object management records for the individual objects to be changed A special authorization that you need to work with the change master record
• •
SAP
SAP
•
When you create a recipe, the new recipe is valid from this date. When you display or change a recipe, the system selects the recipe valid on this date. Unlike recipe maintenance without a change number, the system creates a new change status for all changed recipe objects. This change status is valid from the valid-from date of the change number.
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You can create, change, or display a master recipe with reference to a change master record. The valid-from date in the change master record is then used as the key date. This implies:
Internal
Only
• • •
Changes with a Change Master Record
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Figure 128: Changes with a Change Master Record
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Unit 12: Engineering Change Management, Recipe Approval
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A change becomes effective on a precisely defined date. The changed object is saved twice: in its state before and after the change. The state of the object before the change ends with the valid-to date. The state after the change begins with the valid-from date. Changes are documented in a change master record.
Internal
Only
Structure of a Change Master Record Change header Change number
Partner
Valid-from date Authorization group Reason for change
Use
Object types Master recipes Material BOMs
SAP
SAP
Documents ... Object mgmt records
Use
...
You determine the object types which may be changed with the change master record. One of the functions of the object management record is to enable you to document changes to a specific object.
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In the change header, a short description of the change, the valid-from date, and the status is maintained.
Partner
(for example) Master recipe "Colors"
PLM115
Lesson: Changes with a Change Master Record
Exercise 20: Changes with a Change Master Record Exercise Objectives
Only
Task 1:
For reasons of product safety, some master data changes in your enterprise have to be made with reference to change master records.
Internal
Business Example
Partner
After completing this exercise, you will be able to: • Create change master records
Creating change master records (change numbers) Create two change master records to change master recipes:
SAP
SAP
Cross-Application Components → Engineering Change Management → Change Number → Create
Use
1.
The Create Change Master: Initial Screen appears. Change number: AEND_01_##
Partner
Use
(or) AEND_02_## Type: Change Master
Description:
Change number of group ##
Valid from:
Today + 1 week for AEND_01_## Today + 2 weeks for AEND_02_##
Change no. status:
01 Active
After you choose Enter, the Create Change Master: Object Types screen appears. Define that master recipes and material BOMs can be specified as changeable objects, by choosing Edit → Other → Spec. object types and Continued on next page
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The Create Change Master: Change Header screen appears
Unit 12: Engineering Change Management, Recipe Approval
PLM115
Object type specification: Task list and BOM Choose Copy Set the following indicators for the object types Master recipe and Material BOM: • Actv • Object
Only
Note: By setting these indicators, you define that:
Partner
i) Master recipes and material BOMS (and thus production versions) can be changed with reference to this change number ii) Object management records are automatically created for the changed objects
Internal
• MgtRec
Save your change master records.
Use
Task 2: Changing master recipe objects with change numbers
SAP
Change the master recipe T-DET1## with reference to the change number AEND_01_##
Use
Change the charge quantity range of your recipe to 1000 -40000 L. Save your recipe. 2.
Change your master recipe T-DET1## with reference to the change number AEND_02_##. Change the charge quantity range back to the original value (1000 – 20000 L) for the validity area of the second change number. Display the administrative data for the recipe. Save your recipe again.
3.
Display the header data for recipe T-DET1## and the administrative data for the following key dates: Continued on next page
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Then display the administrative data.
Partner
Access the master recipe from mass maintenance for production versions. Before accessing the recipe, you must assign the change number to the corresponding production version.
SAP
1.
PLM115
Lesson: Changes with a Change Master Record
• Today • Today +10 days • Today + 20 days
Task 3: Documentation of changes
Only
Documentation in the change master record Display the change master record AEND_01_##. Which master recipe was changed with the change number, that is, for which master recipe was an object management record generated?
Partner
_____________________ 2.
Recipe changes
Use
Which changes were made to the recipe header of recipe 1 in recipe group T-DET1##? Use the Recipe Changes reporting function to answer this question.
SAP
______________________________________
SAP
Internal
1.
______________________________________ ______________________________________
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
Solution 20: Changes with a Change Master Record Task 1: Creating change master records (change numbers) 1.
Create two change master records to change master recipes:
Only
The Create Change Master: Initial Screen appears.
Partner
Change number: AEND_01_## (or) AEND_02_##
Internal
Cross-Application Components → Engineering Change Management → Change Number → Create
Type: Change Master
Use
Description:
Change number of group ##
Valid from:
Today + 1 week for AEND_01_##
SAP
SAP
The Create Change Master: Change Header screen appears
Today + 2 weeks for AEND_02_## 01 Active
After you choose Enter, the Create Change Master: Object Types screen appears.
Edit → Other → Spec. object types and Object type specification: Task list and BOM Choose Copy Set the following indicators for the object types Master recipe and Material BOM: • Actv • Object • MgtRec Note: By setting these indicators, you define that: Continued on next page
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Internal
Define that master recipes and material BOMs can be specified as changeable objects, by choosing
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Change no. status:
PLM115
Lesson: Changes with a Change Master Record
i) Master recipes and material BOMS (and thus production versions) can be changed with reference to this change number ii) Object management records are automatically created for the changed objects Save your change master records. a)
See exercise
Changing master recipe objects with change numbers 1.
Change the master recipe T-DET1## with reference to the change number AEND_01_##
Partner
Access the master recipe from mass maintenance for production versions. Before accessing the recipe, you must assign the change number to the corresponding production version.
Use
Change the charge quantity range of your recipe to 1000 -40000 L.
Internal
Only
Task 2:
Then display the administrative data. a)
Production – Process → Master Data → Material Master → Production Versions Group Counter: T-DET1##
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Use
Select production version 0001. Choose the Assign change number icon Change number: AEND_01_##
Internal
SAP
SAP
Save your recipe.
Choose Recipe Recipe header tab Administrative data tab The recipe is now assigned the change number together with its validity range. Save the recipe. Choose the Refresh icon. Continued on next page
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Enter the new charge quantity range as given in the exercise.
Unit 12: Engineering Change Management, Recipe Approval
2.
PLM115
Change your master recipe T-DET1## with reference to the change number AEND_02_##. Change the charge quantity range back to the original value (1000 – 20000 L) for the validity area of the second change number. Display the administrative data for the recipe. Save your recipe again.
3.
Procedure known
Display the header data for recipe T-DET1## and the administrative data for the following key dates: • Today
Partner
• Today +10 days • Today + 20 days Select the production version
Use
a)
Choose Recipe Enter key date.
SAP
SAP
Choose the Display recipe icon. Recipe header and Administrative data tab page
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Documentation of changes Documentation in the change master record Which master recipe was changed with the change number, that is, for which master recipe was an object management record generated? _____________________ a)
(…) → Change Number → Display Change Header screen: Choose All objects There is an object management record for recipe T-DET1## Continued on next page
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Internal
Display the change master record AEND_01_##.
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Task 3: 1.
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a)
PLM115
Lesson: Changes with a Change Master Record
2.
Recipe changes Which changes were made to the recipe header of recipe 1 in recipe group T-DET1##? Use the Recipe Changes reporting function to answer this question. ______________________________________ ______________________________________
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(…) → Master Recipes → Reporting → Recipe → Recipe Changes Task List Type:
2
Plant:
1100
Task List/Recipe Group:
T-DET1##
Group Counter/Recipe:
1
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a)
Internal
______________________________________
Detailed Change Documentation For: Header
SAP
SAP
Program → Execute Changes were made to the lot size (charge quantity range) using the change number from exercise 1.
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
Lesson Summary You should now be able to: • Make changes using change master records
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SAP
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PLM115
Lesson: Recipe Approval
Lesson: Recipe Approval Lesson Overview This lesson familiarizes you with the recipe approval.
Lesson Objectives • •
Create and process engineering change requests / engineering change orders Carry out an approval procedure for master recipes
In part of your company, an approval is needed to create and change master recipes. You get an overview of how ECC Engineering Change Management can be used to map approval procedures for master recipes onto the system.
Engineering Change Request / Order
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Business Example
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After completing this lesson, you will be able to:
SAP
SAP Only
Internal
Use
Partner
Figure 129: Engineering Change Request / Order
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Unit 12: Engineering Change Management, Recipe Approval
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Engineering change orders have the functionality of change master records. However, they comprise the following additional functions: • •
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• •
SAP
SAP
•
It must have been approved and contain at least one object management record If a corresponding change rule has been maintained for the recipe, the change type of the object management record must also be identical to that in the recipe header. To maintain component assignments, material quantity calculation, and the bill of material from within the recipe, you also need an object management record with approved changes for the bill of material.
Use
Partner
You can create, change, or display a master recipe with reference to an engineering change order. The valid-from date of the engineering change order is then used as the key date. The engineering change order must meet the following requirements:
Internal
• •
The possibility of triggering a workflow task, such as sending a message to the person responsible at a particular processing stage A procedure for the approval and release of changes during which an unapproved engineering change request is converted into an approved engineering change order The assignment of a user status profile to extend the system status network The assignment of authorizations for user statuses
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Lesson: Recipe Approval
Structure of an Engineering Change Request
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General header data of the engineering change request:
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•
Allowed object types: •
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You must define the object types that may be changed with the engineering change request. These include, for instance, master recipes, material BOMs, and material master records.
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• •
The engineering change request is identified by the change number you enter. The change type controls the change process for the entire request using a system status profile. You can assign a user status profile and workflow tasks for different processing steps to the change type. The valid-from date specifies the date on which the changes come into effect. By entering an authorization group, you can define that a special authorization is required to maintain the engineering change request. Entering a reason for the change enables you to document planned changes fully.
Partner
• •
SAP
SAP
Figure 130: Structure of an Engineering Change Request
Unit 12: Engineering Change Management, Recipe Approval
PLM115
Creating object management records for objects you want to change: •
•
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Only
•
You must create an object management change record for every object you want to change using the engineering change request. An example for a change object would be a certain master recipe. You maintain a change type for each object management record. The change type controls the change process for the specific object. Entering a reason for the change for an object management record enables you to document planned changes of a particular object fully.
Use
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Change Master Record and Engineering Change Request/Order: Comparison
Internal
Since object management records are not automatically generated for the engineering change request/order, the icon for this does not appear in the object type overview.
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In contrast to the engineering change requests/orders, you may not enter any change types for change master records. There is no system status network for change master records either.
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Figure 131: Change Master Record and Engineering Change Request/Order: Comparison
PLM115
Lesson: Recipe Approval
You cannot use the automatic generation function here, because the engineering change request/order is to control the business processes of requesting, inspecting, and releasing changes for certain assigned objects. This excludes an implied assignment during object change itself (by using the change number). Hint: The example in the graphic corresponds to the default setting for the engineering change request/order.
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Changing Master Recipes
SAP
SAP
To meet these requirements, the SAP R/3 System offers various types of recipe maintenance. You can enter a change rule in the recipe to specify the maintenance procedure that is to be used for a recipe. You can create or change master recipes as follows: Without a change number: All you need is an authorization for the corresponding recipe transactions. Changes are valid for the entire validity period of the selected recipe object version.
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In process industries, requirements for documentation and checking of master recipes vary widely depending on the branch of industry and the product. They range from fairly unrestricted maintenance of recipes over detailed planning, documentation to strict approval procedures.
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Use
Figure 132: Changing Master Recipes
Unit 12: Engineering Change Management, Recipe Approval
PLM115
With a change number: By using a change master record, you can combine the planning and execution of changes to related objects such as recipes, materials, and bills of material. The validity date is specified using a change master record (synonymous with change number). A new change status is created for all changed recipe objects (for example, operation, relationship).
Only Partner
As soon as you have assigned a change rule to a recipe and thus defined that it is subject to a specific change procedure, this recipe is locked for all change procedures that are less restrictive.
Use
Recipe Approval (General Procedure)
Internal
With an engineering change order: With engineering change orders, the functionality of the change master record is enhanced by a detailed approval procedure. By entering a change type, you can specify that the approval procedure must be carried out in a specific user-defined way.
SAP
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Figure 133: Recipe Approval (General Procedure)
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Lesson: Recipe Approval
The change procedure using an engineering change request comprises three main steps: • • •
Creating an engineering change request Checking an engineering change request and converting it into an engineering change order Changing objects and completing the change
Use
Only Partner
Recipes that have already been approved but are changed using another engineering change order are considered unapproved during the period between the conversion and release for the change period defined by the valid-from date. Approval is granted when the change order is released.
Internal
For a master recipe marked with change type 'With engineering change order', this process represents an approval procedure. Once the procedure has been released, the maintained recipe is marked as 'Approved recipe' for the change period defined by the valid-from date of the change request.
Recipe Approval (Status Sequence I)
SAP
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Figure 134: Recipe Approval (Status Sequence I)
The procedure for approving and releasing engineering change requests or orders is controlled via links between statuses and business transactions. The statuses mark particular processing statuses during the approval procedure. They include: • •
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A fixed network of system statuses Company-specific user statuses
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
You can proceed from one status to the next by carrying out a business transaction. SAP has defined a standard approval procedure, which has been implemented via a network of system statuses: 1. An engineering change request is created which describes planned changes to various objects, including master recipes. 2. The planned changes to the individual objects are checked and marked as possible or unnecessary.
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Recipe Approval (Status Sequence II)
Internal
3. After the check, the engineering change request is approved and converted into an engineering change order. Now the changes can be made, that is, the master recipe can be maintained with reference to the engineering change order.
SAP
SAP
Internal
Use
Partner
Figure 135: Recipe Approval (Status Sequence II)
5. The processing of the engineering change order ends with its release. The recipe has now been approved and can be used to create an approved process order. If the approval procedure defined by SAP does not meet all your requirements, you can add company-specific checks at the change order header or change object level. To do so, assign a change type with a corresponding user status profile to the engineering change request or the change object.
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4. After the changes to all objects have been made, the entire engineering change order is completed.
PLM115
Lesson: Recipe Approval
Status profiles are defined and assigned to change types within Customizing for engineering change management. They contain company-specific user statuses. In the status profile, you link these user statuses to the business transactions you carry out, thus inserting them in the existing network of system statuses. You can specify that a special authorization is required to set or delete a user status.
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Unit 12: Engineering Change Management, Recipe Approval
SAP
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PLM115
Lesson: Recipe Approval
Exercise 21: Recipe Approval Exercise Objectives After completing this exercise, you will be able to: • Create and process engineering change requests / engineering change orders • Carry out approval procedures for master recipes
Only
In part of your company, an approval is needed to create and change master recipes.
Partner
You get an overview of how ECC Engineering Change Management can be used to map approval procedures for master recipes onto the system.
Task 1:
Use
Change rule 1.
Internal
Business Example
Select the production version for recipe T-HTB2##. ____________________________
2.
A message exists for the production version. What information does the message contain?
Partner
Use
_____________________________________________ _____________________________________________ Open the master recipe T-TAB## for production version 0001 of material T-HTB2## on the key date Today. To which processing mode (display or change) does the system take you? __________________________________ 4.
Use F1 help, to find out the meaning and function of the “Change rule” and “Change type” fields in the recipe header. Which change rule and change type are set?
Continued on next page
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_____________________________________________ 3.
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SAP
Can you change the production version?
Unit 12: Engineering Change Management, Recipe Approval
PLM115
Change rule: Change type: Save the recipe.
Task 2: 1.
In engineering change management, create change request REQUEST## of change type 200 “Change recipes”.
Change number:
REQUEST##
Type:
Engineering change request
Change type:
200
Use
Partner
Production - Process → Master Data → Engineering Change Management → Change Number → Create
Internal
Only
Creating an engineering change request
Recipe change T-TAB##
Valid from:
Today + 1 week
Change no. status:
01 “Actv”
Reason for change:
Display SOP in PI sheet for T-TAB##
Choose Enter. Allow the changeability of the object types “Master recipe” and “Material BOM”. Edit → Other → Spec. object types Indicator “Task list” and “BOM” Set the “Actv” indicator and “Object” indicator for the object types “Master recipe” and “Material BOM”. Delete all indicators set for other object types. Define recipe T-TAB## and the BOM for material T-HTB2## as change objects. Choose Objects. Continued on next page
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Description:
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Use
Make the following entries on the “Create ECR: Change Header” screen:
SAP
SAP
Choose Enter.
PLM115
Lesson: Recipe Approval
Choose TaskL tab. TLstTy
Group
Description
Change type
2
T-TAB##
Add new proc.inst. for SOP call up.
200
Material
Plant
BOM Usg
Description
Change type
T-HTB2##
1100
1
No change
200
Partner
Enter, for example, the following long text for the object management record with regard to the planned recipe change:
SAP Use
2.
Which statuses are set for your change objects?
Internal
In the relevant object management record for the recipe or BOM: Choose Status mgmt.
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System statuses: ____________________________________ User status: ____________________________________ ____________________________________ ____________________________________ 3.
Which statuses are set for the change request? Continued on next page
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Due to a new safety rating of material T-HTB2##, you must be able to call up the Standard Operating Procedures (SOP) SOP 123-XY from the archive system in the PI sheet for phase 120. You must therefore adjust the address data of process instruction DOC_SHOW for phase 120. The change must be valid from the date today + 1 week.
SAP
(TaskL tab / “Details view” icon for T-TAB## / “Object long text” icon)
Use
Note: You must create an object management record even if you do not plan to change the BOM. Before changing the recipe, you must assign the change order/request to the relevant production version. The system then checks whether valid object management records exist for the recipe and BOM.
Internal
Only
Mat. BOM tab
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
Choose the Change header icon and then Status mgmt. System status ____________________________________ User status: ____________________________________
Task 3: Now try to assign your change request REQUEST## to production version 0001 of material T-HTB2##. The system issues a message. Display the message log. What is the message text for the error message? ______________________________________________________ 2.
Find out more about the reasons for the error and how to fix it by double-clicking the error message.
SAP
SAP
______________________________________________________ ______________________________________________________
Checking, approving, and converting the engineering change request Checking
Internal
Set the status “Check request” for the engineering change request REQUEST##. (...) → Change Number → Change and in the change header: Set status icon
Only
Choose Check req. Choose Continue. 2.
Can you set the object system status “Change possible” for the change management records of the recipe or BOM at the moment? ____________________________________ (In the object management record of the recipe or BOM, choose the Set status icon.) Continued on next page
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Use
Task 4:
1.
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1.
Internal
Only
Save your change request.
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Lesson: Recipe Approval
3.
Before the system status can be set, the persons authorized to do so must first revoke the user statuses taking effect at the moment. Revoke the user statuses for the objects Recipe and BOM. (In the object management record of the recipe or BOM, choose Status mgmt and remove the indicators for the user statuses.)
4.
Set the system status “Change possible” for the objects.
Only
5.
Approving and converting Which additional system status was set for the change header? (In the change header, choose Status mgmt.)
6.
Set the system status to “ECR checked”. (In the change header, choose the Set status icon. Choose Request checked.) The request must now be approved and converted to an engineering change order before the change objects can be processed. Before you can set the corresponding status, the user status BETR that is already set must be withdrawn by an authorized person.
Use
(In the change header, choose Status mgmt. and remove the indicator for user status BETR.
Internal
In the change header, choose the Set status icon. Choose Request checked. Choose Convert request)
Only
Save your engineering change order.
Task 5: Changing with an engineering change order 1.
Now change your master recipe T-TAB## with reference to your engineering change order REQUEST##. First, select the production version for material T-HTB2## and assign request REQUEST## to the production version. Continued on next page
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Partner
Withdraw the user status and set the system status “Approve request” and “Convert request”.
SAP
SAP
7.
Use
Partner
_____________________________________
Internal
(In the object management record of the recipe or BOM, choose the Set status icon and then choose Change possible.)
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
Access the recipe. You can now change the recipe. Change the process instruction DOC_SHOW for phase 120. Call up the process instruction in the PI assistant and enter the new value SOP 123-XY for parameter DOCUMENT in the import parameters for the function call. Save the changed recipe.
Task 6:
Only
1.
Call up your engineering change order REQUEST## in the change mode. Which statuses does the engineering change order have?
Partner
_____________________________________ _____________________________________
Use
_____________________________________ _____________________________________
SAP
_____________________________________
SAP
Use
Which statuses do the change objects have? _____________________________________ _____________________________________ _____________________________________
Partner
2.
Set the status “Complete change” for the change objects. Which system statuses do the change objects have now?
Internal
Internal
Closing and releasing object changes and engineering change orders
_____________________________________ _____________________________________
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_____________________________________ Which user statuses were set when you closed? _____________________________________ _____________________________________ _____________________________________
Continued on next page
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Lesson: Recipe Approval
The change objects can only be released after being inspected by the responsible areas defined by the user statuses. These authorized users withdraw their user status after inspection, and the object can then be released. Withdraw the user statuses for the change object and then set the system status “Release change”. 3.
Set the system status “Complete order” for the engineering change order.
Only Partner
_____________________________________
SAP
The engineering change order can only be released and the corresponding approval granted after being inspected by the responsible area defined by the order user status BETR. An authorized person withdraws the user status after inspection and releases the order.
SAP
Withdraw the user status BETR for the order and set the order system status to “Release change”.
Partner
Internal
_____________________________________
Use
Which system statuses does the engineering change order have now? _____________________________________ _____________________________________ _____________________________________
Use
_____________________________________ Which user status was set while closing? _____________________________________
Internal
Save your engineering change order.
Task 7: 1.
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Only
Status report on engineering change order Display a detailed status report on your engineering change order.
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
Solution 21: Recipe Approval Task 1: Change rule 1.
Select the production version for recipe T-HTB2##. Can you change the production version?
Only
a)
Production – Process → Master Data → Material Master → Production Versions You cannot change the production version.
2.
A message exists for the production version. What information does the message contain? _____________________________________________ _____________________________________________
SAP
a)
The message tells you that the production version belongs to a recipe requiring approval.
Use Internal
3.
Open the master recipe T-TAB## for production version 0001 of material T-HTB2## on the key date Today. To which processing mode (display or change) does the system take you? a)
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__________________________________ Select production version 0001. Choose Recipe The system takes you to the display mode. 4.
Use F1 help, to find out the meaning and function of the “Change rule” and “Change type” fields in the recipe header. Which change rule and change type are set? Continued on next page
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You cannot change the production version, recipe, or BOM until a valid engineering change order has been assigned.
SAP
_____________________________________________
Use
Partner
Material: T-HTB2##
Internal
____________________________
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Lesson: Recipe Approval
Change rule: Change type: Save the recipe. Recipe header tab Change rule:
“With engineering change order (with change type)”
Change type:
200 “Change recipes”
Creating an engineering change request 1.
In engineering change management, create change request REQUEST## of change type 200 “Change recipes”.
REQUEST##
Type:
Engineering change request
Change type:
200
Partner
Use
Change number:
SAP
SAP
Production - Process → Master Data → Engineering Change Management → Change Number → Create
Choose Enter.
Description:
Recipe change T-TAB##
Valid from:
Today + 1 week
Change no. status:
01 “Actv”
Reason for change:
Display SOP in PI sheet for T-TAB##
Choose Enter. Allow the changeability of the object types “Master recipe” and “Material BOM”. Edit → Other → Spec. object types Continued on next page
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Internal
Make the following entries on the “Create ECR: Change Header” screen:
2005/Q2
Use
Partner
Task 2:
Internal
Only
a)
Unit 12: Engineering Change Management, Recipe Approval
PLM115
Indicator “Task list” and “BOM” Set the “Actv” indicator and “Object” indicator for the object types “Master recipe” and “Material BOM”. Delete all indicators set for other object types. Define recipe T-TAB## and the BOM for material T-HTB2## as change objects. Choose Objects.
Group
Description
Change type
2
T-TAB##
Add new proc.inst. for SOP call up.
200
Mat. BOM tab BOM Usg
Description
Change type
T-HTB2##
1100
1
No change
200
Due to a new safety rating of material T-HTB2##, you must be able to call up the Standard Operating Procedures (SOP) SOP 123-XY from the archive system in the PI sheet for phase 120. You must therefore adjust the address data of process instruction DOC_SHOW for phase 120. The change must be valid from the date today + 1 week.
Partner
SAP
SAP
Enter, for example, the following long text for the object management record with regard to the planned recipe change: (TaskL tab / “Details view” icon for T-TAB## / “Object long text” icon)
a) 2.
Production - Process → Master Data → Engineering Change Management → Change Number → Create
Which statuses are set for your change objects? In the relevant object management record for the recipe or BOM: Choose Status mgmt. Continued on next page
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Only
Note: You must create an object management record even if you do not plan to change the BOM. Before changing the recipe, you must assign the change order/request to the relevant production version. The system then checks whether valid object management records exist for the recipe and BOM.
Use
Plant
Internal
Material
Use
Partner
TLstTy
Internal
Only
Choose TaskL tab.
PLM115
Lesson: Recipe Approval
System statuses: ____________________________________ User status: ____________________________________ ____________________________________ ____________________________________
Only
System statuses:
Internal
a)
Created User status:
Partner
CHEM: Check by chemist QUAL: Check by quality assurance 3.
Use
PROC: Check by process technology Which statuses are set for the change request?
SAP
____________________________________
SAP
System status
Use
Choose the Change header icon and then Status mgmt. ____________________________________ User status:
Partner
Save your change request.
Internal
a)
System status Created
Only
User status: Check by plant management
Task 3: Now try to assign your change request REQUEST## to production version 0001 of material T-HTB2##. 1.
The system issues a message. Display the message log. What is the message text for the error message? Continued on next page
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Unit 12: Engineering Change Management, Recipe Approval
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______________________________________________________ a)
(...) → Production Versions Message log / message text for error message: System status: ECR is not yet approved
2.
Find out more about the reasons for the error and how to fix it by double-clicking the error message.
Only
______________________________________________________ a)
Reasons for the error and how to fix it:
Use
Partner
The system checks the system status of the engineering change request. The engineering change request must be approved and converted to an engineering change order.
Task 4: Checking, approving, and converting the engineering change request
SAP
Set the status “Check request” for the engineering change request REQUEST##. (...) → Change Number → Change and in the change header: Set status icon
Use
Partner
Choose Check req. Choose Continue. a)
See exercise
Can you set the object system status “Change possible” for the change management records of the recipe or BOM at the moment? ____________________________________ (In the object management record of the recipe or BOM, choose the Set status icon.) a)
3.
No, the user statuses must first be withdrawn.
Before the system status can be set, the persons authorized to do so must first revoke the user statuses taking effect at the moment. Revoke the user statuses for the objects Recipe and BOM. Continued on next page
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2.
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Checking 1.
Internal
______________________________________________________
PLM115
Lesson: Recipe Approval
(In the object management record of the recipe or BOM, choose Status mgmt and remove the indicators for the user statuses.) a) 4.
See exercise
Set the system status “Change possible” for the objects. (In the object management record of the recipe or BOM, choose the Set status icon and then choose Change possible.)
5.
See exercise
Internal
Only
a)
Approving and converting Which additional system status was set for the change header? (In the change header, choose Status mgmt.) a)
6.
Status: All objects checked
Set the system status to “ECR checked”. (In the change header, choose the Set status icon. Choose Request checked.)
SAP
The request must now be approved and converted to an engineering change order before the change objects can be processed. Before you can set the corresponding status, the user status BETR that is already set must be withdrawn by an authorized person. Withdraw the user status and set the system status “Approve request” and “Convert request”.
Internal
(In the change header, choose Status mgmt. and remove the indicator for user status BETR.
Only
In the change header, choose the Set status icon. Choose Request checked. Choose Convert request) Save your engineering change order. a)
See exercise
Continued on next page
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Use
7.
See exercise
SAP
a)
Use
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_____________________________________
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
Task 5: Changing with an engineering change order 1.
Now change your master recipe T-TAB## with reference to your engineering change order REQUEST##. First, select the production version for material T-HTB2## and assign request REQUEST## to the production version. Change the process instruction DOC_SHOW for phase 120. Call up the process instruction in the PI assistant and enter the new value SOP 123-XY for parameter DOCUMENT in the import parameters for the function call.
Partner
Save the changed recipe. a)
(...) → Production Versions
Use
Material: T-HTB2## Select the production version Choose the Assign change number icon.
SAP
SAP
Assign REQUEST##. Choose Recipe Operations tab
Use
Partner
Select phase 120 and choose the Proc.instr. icon. Change DOC_SHOW as described in the exercise.
Task 6: Closing and releasing object changes and engineering change orders Call up your engineering change order REQUEST## in the change mode. Which statuses does the engineering change order have? _____________________________________ _____________________________________ _____________________________________ _____________________________________ Continued on next page
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Internal
Save the recipe.
1.
Internal
Only
Access the recipe. You can now change the recipe.
PLM115
Lesson: Recipe Approval
Which statuses do the change objects have? _____________________________________ _____________________________________ _____________________________________ _____________________________________
Only Partner
ECR checked
Statuses of the change objects:
Choose the Details view icon.
Internal
Statuses of the change order:
SAP
(...) → Change Number → Change
Use
a)
(In the change header, choose Status mgmt.) All objects checked ECR approved
Use
ECO to be processed Choose Back.
SAP
Choose Objects. Select both objects.
Partner
Choose Status mgmt.
Internal
Created Object: Change possible
Only
Object: To be processed Object: In process Choose Back. 2.
Set the status “Complete change” for the change objects. Which system statuses do the change objects have now? _____________________________________ _____________________________________ Continued on next page
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
_____________________________________ Which user statuses were set when you closed? _____________________________________ _____________________________________ _____________________________________
Only
Withdraw the user statuses for the change object and then set the system status “Release change”.
Partner
a)
Set the status “Complete change” for the change objects. In the relevant object management record, choose the Set status icon
Use
Choose Complete changes. Choose Continue in the relevant object management record.
SAP
User status:
SAP
Use
Choose Status mgmt. System status: Created
Internal
The change objects can only be released after being inspected by the responsible areas defined by the user statuses. These authorized users withdraw their user status after inspection, and the object can then be released.
Object: Change possible Object: Change completed
Partner
CHEM: Check by chemist
Internal
QUAL: Check by quality assurance PROC: Check by process technology
Only
For the relevant object in status management: Remove all indicators for the user statuses. Choose Back. Choose the Set status icon. Choose Release changes. Choose Continue. 3.
Set the system status “Complete order” for the engineering change order. Continued on next page
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PLM115
Lesson: Recipe Approval
Which system statuses does the engineering change order have now? _____________________________________ _____________________________________ _____________________________________ _____________________________________
Only
_____________________________________
Withdraw the user status BETR for the order and set the order system status to “Release change”.
Use
The engineering change order can only be released and the corresponding approval granted after being inspected by the responsible area defined by the order user status BETR. An authorized person withdraws the user status after inspection and releases the order.
Which user status was set while closing?
Internal
_____________________________________
Partner
_____________________________________
SAP
SAP Only
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Continued on next page
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
Save your engineering change order. a)
Choose the Change header icon. Choose the Set status icon. Choose Complete order. Choose Continue. System statuses of the change order:
Only
Internal
Choose Status mgmt. All objects checked
Partner
ECR approved
SAP
Check by plant management
Use
ECR checked
Choose the Set status icon.
ECO confirmed
Use
ECO completed All objects released User status:
SAP
Remove indicator for user status Choose Back.
Internal
A message appears that the engineering change order has been released. Choose Continue.
Only
Save order
Continued on next page
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Choose Release order.
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PLM115
Lesson: Recipe Approval
Task 7: Status report on engineering change order 1.
Display a detailed status report on your engineering change order. a)
(...) → Change Number → Change Choose Enter (if warnings occur, choose Enter to confirm). Environment → Reporting → Status Report
Only
Internal
or
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Status report icon for system status
SAP
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Unit 12: Engineering Change Management, Recipe Approval
PLM115
Lesson Summary You should now be able to: • Create and process engineering change requests / engineering change orders • Carry out an approval procedure for master recipes
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SAP
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PLM115
Unit Summary
Unit Summary You should now be able to: • Describe the principle of using the engineering change management • Make changes using change master records • Create and process engineering change requests / engineering change orders • Carry out an approval procedure for master recipes
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SAP
SAP Only
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Unit Summary
PLM115
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Test Your Knowledge
What do we want to achieve by using the engineering change management?
2.
Explain the structure of a change master record.
3.
Name the keywords for the change procedure using an engineering change request.
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1.
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Test Your Knowledge
SAP
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Test Your Knowledge
PLM115
Answers 1.
What do we want to achieve by using the engineering change management? Answer:
Only
Explain the structure of a change master record. Answer: •
Change header: In the change header, a description of the change, the valid-from date, and the status is maintained. Object types: You determine the object types which may be changed with the change master record.
•
Object mgmt records:
Use Internal
3.
Name the keywords for the change procedure using an engineering change request.
• • • • • •
462
Only
Answer: Creating engineering change request Checking planned changes Approving the changes Applying engineering change request in change order Making the object changes Completing and releasing changes/ engineering change order
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One of the functions of the object management record is to enable you to document changes to a specific object.
SAP
SAP
•
Use
Partner
2.
Planning and realization of master data changes at a specified time Monitoring and documentation of changes Storing a number of change statuses for different times Grouping of related changes
Internal
• • • •
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Unit 13 Unit Overview
Unit Objectives After completing this unit, you will be able to:
• •
Describe the principle of material costing with a quantity structure. Describe the principle of the integration of the ECC and SCM (APO) software components. Describe the basics of recipe management. Describe the transformation of a general recipe into a master recipe.
Use
Only
Internal
Lesson: Material Costing .......................................................... 464 Lesson: Integration of ECC and SCM (APO) ................................... 467 Lesson: Basics of Recipe Management ......................................... 473
Partner
Unit Contents
SAP
SAP
• •
Use
Partner
The appendix introduces you to fundamental aspects of material costing, integration (ECC - SCM APO) and recipe management.
Internal
Only
Appendix
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Unit 13: Appendix
PLM115
Lesson: Material Costing Lesson Overview This lesson familiarizes you with the principle of the material costing with a quantity structure.
Lesson Objectives
Only
•
Describe the principle of material costing with a quantity structure.
Partner
Business Example You have to regularly perform material costing with a quantity structure for your materials produced in-house.
Internal
After completing this lesson, you will be able to:
Use
SAP
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Internal
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Figure 136: Material Costing: Objectives
Material costing uses data from Logistics, such as the material BOM and the master recipe, as the quantity structure to calculate costs for material consumption and the activities.
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Lesson: Material Costing
Material costing valuates this quantity structure with: • • • • •
Prices for materials in the material master Prices for activities in Cost Center Accounting Prices for processes in Activity-Based Costing Overhead on the direct costs for these materials and activities Overhead for sales and administration costs
Internal
Only
You can analyze the results in different ways. The analysis is, for example, used for pricing or valuation.
Use
Partner
Executing a Material Cost Estimate
SAP
SAP
When you create a cost estimate with a quantity structure, you enter the costing variant, the material, the plant, and the costing version. If you do not enter a costing lot size, the default value from the material master record is used. The system determines and valuates the quantity structure automatically. The dates are proposed from the costing variant and determine the following: • • •
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The valuation date for the materials and activities The validity period of the cost estimate (costing date from/to) The determination of the quantity structure (quantity structure date)
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Figure 137: Executing a Material Cost Estimate
Unit 13: Appendix
PLM115
Lesson Summary You should now be able to: • Describe the principle of material costing with a quantity structure.
Use
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Only
Internal
SAP
SAP Only
Internal
Use
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PLM115
Lesson: Integration of ECC and SCM (APO)
Lesson: Integration of ECC and SCM (APO) Lesson Overview This lesson gives you an overview of the integration of the ECC and SCM (APO) software components.
Only
Business Example
•
Describe the principle of the integration of the ECC and SCM (APO) software components.
Your enterprise wants to use the software component SCM (APO).
Internal
After completing this lesson, you will be able to:
Partner
Lesson Objectives
Use
Supply Chain Master Data in ECC and SCM (APO)
SAP
SAP Only
Internal
Use
Partner
Figure 138: Supply Chain Master Data in ECC and SCM (APO)
The APO Core Interface (CIF) defines and controls the data transfer between ECC and SCM (APO) Systems. The CIF is the central interface for connecting SCM (APO) to the existing ECC System environment.
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Unit 13: Appendix
PLM115
APO-CIF is a real-time interface. Out of the ECC's complex data quantity, only those data objects that are needed for planning and optimization processes in the SCM (APO) data structures suited for supply chain planning are transferred to SCM (APO). To specify which master and transaction data is transferred to SCM (APO), you define an integration model in ECC. Both the initial data transfer (initial transfer) and the data changes (transfer of data changes) within SCM (APO) take place using the SCM (APO) Core Interface (CIF).
Only
An RFC connection with the ECC System is a technical requirement for successful data transfer into SCM (APO) using the Core Interface.
Initial Transfer of Master Data: Overview
Use
Partner
The ECC System remains the dominant system for the master data. You only create that specific SCM (APO) master data that does not exist in ECC, directly in SCM (APO).
Internal
The master data objects in SCM (APO) are generally not identical to those in ECC. For the master data transfer, it is in fact the relevant ECC master data that is mapped onto the corresponding planning master data in SCM (APO).
SAP
SAP
You define the integration model that controls the transfer of master and transaction data in the ECC System. You can find the menu option “Core Interface Advanced Planner and Optimizer” (the “CIF menu”) under Logistics → Central Functions → Supply Chain Planning Interface.
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Figure 139: Initial Transfer of Master Data: Overview
PLM115
Lesson: Integration of ECC and SCM (APO)
The integration model distinguishes between master data and transaction data. We recommend that you select the two types of data in separate integration models and then transfer them separately. In the integration model, you select the dataset (master or transaction data) that you want to transfer. You specify the following in the integration model: • •
The SCM (APO) target system for the data transfer The data objects you want to transfer
Only
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ECC Master Recipe and SCM (APO) PPM
Internal
You can delete integration models that you no longer need, but note that you must first deactivate them.
SAP
SAP
Internal
Use
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Figure 140: ECC Master Recipe and SCM (APO) PPM
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Unit 13: Appendix
PLM115
Phase/Activity Relationships
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Internal
Figure 141: Phase/Activity Relationships
SAP
SAP Only
Internal
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Lesson: Integration of ECC and SCM (APO)
Transaction Data of the Supply Chain in ECC and SCM (APO)
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As for master data, an initial data transfer of transaction data also takes place first. This is usually followed automatically by the incremental data transfer between ECC and SCM (APO) for transaction data objects that are members of an active integration model. This means that new transaction data or changes to existing transaction data are transferred automatically.
Partner
To specify which transaction data is transferred to SCM (APO), you also define an integration model in ECC. The transaction data is mapped to orders in SCM (APO) that differ by ATP category. This means that the transaction data objects of SCM (APO) are not identical to those of ECC. Object mapping takes place via the Core Interface.
SAP
SAP
Use
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Only
Internal
Figure 142: Transaction Data of the Supply Chain in ECC and SCM (APO)
Unit 13: Appendix
PLM115
Lesson Summary You should now be able to: • Describe the principle of the integration of the ECC and SCM (APO) software components.
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Internal
SAP
SAP Only
Internal
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PLM115
Lesson: Basics of Recipe Management
Lesson: Basics of Recipe Management
Partner
•
Recipe management
• •
– Application – Recipe types – PLM and SCM integration – Recipe elements – Required application components Recipe workbench Transformation of a general recipe into a master recipe
Internal
Only
Lesson Overview
Use
Lesson Objectives After completing this lesson, you will be able to:
SAP
Describe the basics of recipe management. Describe the transformation of a general recipe into a master recipe.
SAP
• •
Business Example
Use Internal
The scope of the functions should range from the detailed definition of cross-enterprise product specifications and the additional definition of special location-independent properties to the creation of recipies that can be used productively in the individual plants.
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For this purpose, you decide to introduce the SAP Recipe Management.
Partner
To support the product development in your enterprise, you need a tool for the development of recipes.
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Unit 13: Appendix
PLM115
Recipe Management: Application
Use
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Only
Internal
SAP
SAP
Figure 143: Recipe Management: Application
The recipe management
Use
•
Supports the development process of a product Becomes active at the product idea stage and accompanies the process all the way to the detailed specification and process definition Supports and enables communication between areas
Internal
Target group/customer group: •
474
Process industries - emphasis on consumer packaged goods, chemical and pharmaceutical industries
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The recipe is the central object of the recipe management. You use it to describe the manufacturing of products and the execution of a process. Recipes include information on the products and components of a process, the process steps to be carried out, and the resources required for the production.
Partner
• •
PLM115
Lesson: Basics of Recipe Management
User group: •
Central product development
•
– Developing new products and changing and adapting exisiting products Production area –
Converting recipies into production recipes
Only
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Internal
Recipe Types
Internal
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Recipes are used on different enterprise levels. They form the basis for cross-enterprise investment decisions and for location-related long-term planning and for applying a process on site. You use the recipe types of the recipe management to create, as required, a general description of the requirements or a concrete process rule. By specifying the data for cross-enterprise recipes, you derive location- and branch-specific recipes from them.
Partner
Use
SAP
SAP
Figure 144: Recipe Types
Unit 13: Appendix
PLM115
PLM and SCM Integration
Partner
The branch-specific master recipe of the recipe management is not yet integrated into the standard processes of the SAP production planning. However, by linking the master recipe with a production version, you create a reference to the productively usable master recipe and the BOM of the SAP standard system.
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Internal
Figure 145: PLM and SCM Integration
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Lesson: Basics of Recipe Management
Recipes: Elements and Integration
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Internal SAP
SAP
Figure 146: Recipes: Elements and Integration
•
Environment, Health and Safety (EH&S)
Use
•
Engineering Change Management (LO-ECH)
Internal
Change management •
Classification System (CA-CL)
Only
Classification of recipes Property tree and evaluations in formulas, and evaluations in the recipe •
Quality Planning (QM-PT) Recording data for the quality inspection
•
Basic Data (production planning for process industries) (PP-PI-MD) Assigning a production version to the recipe
•
Material Master (LO-MD-MM) Recording material data in formulas
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Processing recipe formulas and information systems and generating formula data and reports
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Unit 13: Appendix
PLM115
Recipe Workbench
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Internal
SAP Use
The screen is divided into the navigation area and the application area.
•
The navigation area shows a navigation tree, a symbol bar that supports the navigation, and a detail area showing the structure details of the selected object. The application area shows the data of the selected objects and the status menu. It is also a selection and result area of the information systems for the individual objects.
It supports drag & drop functions to pull, create and copy objects between different screen areas and within the same screen area. A personalization function allows you to save individual user settings for the workbench.
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Internal
•
Partner
The recipe workbench is the initial screen for the simultaneous processing of different application objects in the Recipe Management. You can use the workbench to navigate between different applications within a single interface.
SAP
Figure 147: Recipe Workbench
PLM115
Lesson: Basics of Recipe Management
Recipe Transformation in Master Recipes (I)
SAP Use
The system generates the BOM from the formula of the general recipe or from the formulas of the selected general recipe steps.
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The resource assignments are also defined.
Partner
General recipe actions and process parameters provide information for master recipe process instructions.
A general recipe can be transformed into a master recipe. The general recipe serves as a template for the production version, the master recipe and the BOM.
SAP
General recipe steps are transformed into master recipe operations and general recipe operations are transformed into master recipe phases. Master recipe operations can be divided up or combined after the transformation.
Internal
Use
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Internal
Figure 148: Recipe Transformation in Master Recipes (I)
Unit 13: Appendix
PLM115
Prerequisites: • •
You have made the necessary settings for transforming the master recipe. Make sure that all the master data is in the target system in which you want to create the master recipe.
Only Partner
Material master Classes Resources Resource classification Master inspection characteristics Inspection methods Process instruction category and process instruction characteristic
Internal
– – – – – – –
Recipe Transformation in Master Recipes (II)
Use
SAP
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Internal
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Figure 149: Recipe Transformation in Master Recipes (II)
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PLM115
Lesson: Basics of Recipe Management
BOM •
Resources
•
•
SAP
SAP
•
The first equipment requirement of the general recipe step provides information for the resource selection conditions of the master recipe operation. The classification of the equipment requirements of each general recipe step is copied to the resource selection conditions of the relevant master recipe operation. The first equipment requirement of each general recipe step defines the primary resource of the corresponding master recipe operation. The remaining equipment requirements of the general recipe step define the secondary resources for the master recipe operation. The equipment requirements of the general recipe operations define the secondary resources of the master recipe phases. The equipment requirements on the general recipe and process action levels are not considered in the transformation.
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Partner
•
Internal
Only
•
The system generates the BOM from the formula of the general recipe or from the formulas of the selected general recipe steps. When the formula is assigned to the process step, the system aggregates the formulas of the steps selected and generates the BOM from this aggregated formula. The system assigns the material components of the generated BOM to the master recipe operations or phases. This depends on the formula components that were assigned to the steps or operations of the general recipe.
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Unit 13: Appendix
PLM115
Recipe Transformation in Master Recipes (III)
SAP
Only
Internal
Partner
To transform process parameters into process instructions, you must ensure that you have assigned the correct ABAP class to the object type PROCPARA in the transformation group. You do this in the Customizing for the master recipe transformation, under Define transformation groups. SAP provides the standard ABAP class CL_RMXM_ROM_PP.
Process instructions You can assign process parameters to the general recipe, the process step, the process operation, the process action and the equipment requirement.
SAP
Use
Use
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Internal
Figure 150: Recipe Transformation in Master Recipes (III)
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Lesson: Basics of Recipe Management
Process parameters are transformed in the master recipe as follows: •
Process parameters belonging to (1) Recipe: Assignment to the first phase of the first master recipe operation Equipment for recipe: no transformation (2) Process step: Assignment to the first phase of the corresponding master recipe operation
Only
(3) Process operation: Assignment to the corresponding phase
Partner
(3) Equipment for process operation: Assignment to the corresponding phase (4) Process action: Assignment to the superordinate phase
Internal
(2) Equipment for process step: Assignment to the first phase of the corresponding master recipe operation
(4) Equipment for process action: Assignment to the superordinate phase
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Unit 13: Appendix
PLM115
Lesson Summary You should now be able to: • Describe the basics of recipe management. • Describe the transformation of a general recipe into a master recipe.
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Internal
SAP
SAP Only
Internal
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484
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2005/Q2
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PLM115
Unit Summary
Unit Summary You should now be able to: • Describe the principle of material costing with a quantity structure. • Describe the principle of the integration of the ECC and SCM (APO) software components. • Describe the basics of recipe management. • Describe the transformation of a general recipe into a master recipe.
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Unit Summary
PLM115
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
486
© 2005 SAP AG. All rights reserved.
2005/Q2
Contact for Buying SAP Module Materials:
[email protected] Visit: www.sapeducation.co.nr
PLM115
Test Your Knowledge
What data from the Logistics area is used in the material costing with a quantity structure, and for what purpose?
2.
What is the function of inspection lots?
3.
Where do you define the selection of master and transaction data that is transferred from ECC and SCM (APO)?
4.
Which recipe types are differentiated in the recipe management?
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Test Your Knowledge
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Internal
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2005/Q2
© 2005 SAP AG. All rights reserved.
487
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Test Your Knowledge
PLM115
Answers 1.
What data from the Logistics area is used in the material costing with a quantity structure, and for what purpose?
Only
Answer: Inspection lots document the entire inspection process, from inspection specifications to inspection results recording, and to the usage decision. Where do you define the selection of master and transaction data that is transferred from ECC and SCM (APO)? Answer: You define them in an integration model, which you define in ECC. Which recipe types are differentiated in the recipe management?
SAP
SAP
4.
Answer: General recipe (for cross-enterprise product specification) Site recipes (Plant-specific) master recipes
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Internal
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• • •
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Use
3.
What is the function of inspection lots?
Internal
2.
Partner
Answer: The material BOM and the master recipe are used as the quantity structure to calculate costs for material consumption and the activities.
488
© 2005 SAP AG. All rights reserved.
2005/Q2
Contact for Buying SAP Module Materials:
[email protected] Visit: www.sapeducation.co.nr
PLM115
Course Summary
Course Summary You should now be able to: •
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• • • •
Creating and managing materials, resources, production versions, master recipes, and material BOMs Using engineering change management for recipe approval Mapping the manufacture of co-products onto the system Mapping quality inspection during production onto the system Making important system settings
SAP
SAP Only
Internal
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2005/Q2
© 2005 SAP AG. All rights reserved.
489
Contact for Buying SAP Module Materials:
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Course Summary
PLM115
Use
Partner
Only
Internal
SAP
SAP Only
Internal
Use
Partner
490
© 2005 SAP AG. All rights reserved.
2005/Q2
Contact for Buying SAP Module Materials:
[email protected] Visit: www.sapeducation.co.nr
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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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2005/Q2
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