PLM11Basic+Data,+Part+2

PLM111 Basic Data, Part 2 mySAP Product Lifecycle Management

Date Training Center Instructors Education Website

Participant Handbook Course Version: 2003 Q2 Course Duration: 3 Day(s) Material Number: 50070778

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

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

Trademarks •

Microsoft®, WINDOWS®, NT®, EXCEL®, Word®, PowerPoint® and SQL Server® are registered trademarks of Microsoft Corporation.

•

IBM®, DB2®, OS/2®, DB2/6000®, Parallel Sysplex®, MVS/ESA®, RS/6000®, AIX®, S/390®, AS/400®, OS/390®, and OS/400® are registered trademarks of IBM Corporation.

•

ORACLE® is a registered trademark of ORACLE Corporation.

•

INFORMIX®-OnLine for SAP and INFORMIX® Dynamic ServerTM are registered trademarks of Informix Software Incorporated.

•

UNIX®, X/Open®, OSF/1®, and Motif® are registered trademarks of the Open Group.

•

Citrix®, the Citrix logo, ICA®, Program Neighborhood®, MetaFrame®, WinFrame®, VideoFrame®, MultiWin® and other Citrix product names referenced herein are trademarks of Citrix Systems, Inc.

•

HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C®, World Wide Web Consortium, Massachusetts Institute of Technology.

•

JAVA® is a registered trademark of Sun Microsystems, Inc.

•

JAVASCRIPT® is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape.

•

SAP, SAP Logo, R/2, RIVA, R/3, SAP ArchiveLink, SAP Business Workflow, WebFlow, SAP EarlyWatch, BAPI, SAPPHIRE, Management Cockpit, mySAP.com Logo and mySAP.com are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies.

Disclaimer THESE MATERIALS ARE PROVIDED BY SAP ON AN "AS IS" BASIS, AND SAP EXPRESSLY DISCLAIMS ANY AND ALL WARRANTIES, EXPRESS OR APPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO THESE MATERIALS AND THE SERVICE, INFORMATION, TEXT, GRAPHICS, LINKS, OR ANY OTHER MATERIALS AND PRODUCTS CONTAINED HEREIN. IN NO EVENT SHALL SAP BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES OF ANY KIND WHATSOEVER, INCLUDING WITHOUT LIMITATION LOST REVENUES OR LOST PROFITS, WHICH MAY RESULT FROM THE USE OF THESE MATERIALS OR INCLUDED SOFTWARE COMPONENTS.

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

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

Description

Example text

Words or characters that appear on the screen. These include field names, screen titles, pushbuttons as well as menu names, paths, and options. Also used for cross-references to other documentation both internal (in this documentation) and external (in other locations, such as SAPNet).

2003/Q2

Example text

Emphasized words or phrases in body text, titles of graphics, and tables

EXAMPLE TEXT

Names of elements in the system. These include report names, program names, transaction codes, table names, and individual key words of a programming language, when surrounded by body text, for example SELECT and INCLUDE.

Example text

Screen output. This includes file and directory names and their paths, messages, names of variables and parameters, and passages of the source text of a program.

Example text

Exact user entry. These are words and characters that you enter in the system exactly as they appear in the documentation.



Variable user entry. Pointed brackets indicate that you replace these words and characters with appropriate entries.

© 2004 SAP AG. All rights reserved.

iii

About This Handbook

PLM111

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

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

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

iv

© 2004 SAP AG. All rights reserved.

2003/Q2

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

Unit 1: Overview of Organizational Structures & PP Basic Data ....................1 Overview of PP Basic Data.................................................................. 2 Organizational Levels and Master Data in Production................................... 5

Unit 2: Displaying Routings................................................................ 23 Routing Structure and Routing Types.................................................... 24

Unit 3: Work Center .......................................................................... 35 Work Center Data, Default Data, Work Center Hierarchy ............................. 36 Reporting and Mass Changes ............................................................ 53

Unit 4: Creating a Routing.................................................................. 59 Structure of the Engineering Workbench Interface..................................... 60 Creating a Routing and Material Assignment ........................................... 65 Production Resources/Tools .............................................................. 68

Unit 5: Engineering Workbench........................................................... 83 Structure of the Engineering Workbench ................................................ 84 Using Different Working Areas and Selection Options................................. 97

Unit 6: Processing Routings .............................................................. 113 Sequences in Routings ................................................................... 115 Suboperations and User-Defined Fields................................................ 120 Reference Operation Set, Work Center Operation Set ............................... 125 Scrap and Its Effects ...................................................................... 135 Reporting and Mass Changes ........................................................... 138 Task List Changes with the Change Master............................................ 141

Unit 7: Scheduling...........................................................................155 Understanding Lead Time Scheduling and Material Master Updates .............. 156 Work Center Integration .................................................................. 160

2003/Q2

© 2004 SAP AG. All rights reserved.

v

Contents

PLM111

Formula Connections ..................................................................... 165 Time Components, Reduction Possibilities ............................................ 169

Appendix 1: Menu Paths

................................................................183

Appendix 2: Extra Slides

................................................................187

Appendix 3: Data Used in the Exercises

vi

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

© 2004 SAP AG. All rights reserved.

2003/Q2

Course Overview This course covers the following topics: • • • •

Displaying and scheduling routings Creating and changing routings using the Engineering Workbench Changing routings with and without a history Creating and maintaining work centers

The information in this training course refers to the following SAP software components and releases: •

SAP R/3 Enterprise Release 47

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

Project team members (consultants, business requirements analysts, key users) Employees in work scheduling

Course Prerequisites Required Knowledge • •

A knowledge of production planning and control PLM100 – Life-Cycle Data Management

Recommended Knowledge •

SCM300 – Supply chain manufacturing overview

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

2003/Q2

Explain the organizational structures and basic data in PP Describe the manufacturing functions that support work centers and routings Participate in configuration decisions that ensure that SAP R/3 supports company requirements

© 2004 SAP AG. All rights reserved.

vii

Course Overview

PLM111

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

Maintain routings and work centers Assign material components to operations Determine lead time and enter it in the material master

SAP Software Component Information The information in this course pertains to the following SAP Software Components and releases:

viii

© 2004 SAP AG. All rights reserved.

2003/Q2

Unit 1 Overview of Organizational Structures & PP Basic Data Unit Overview This unit provides an overview of the SAP R/3 organizational structures used in production. It describes the roles of PP basic data elements such as the material master, bills of materials, work centers, routings, and production resources and tools. You will learn how documents are managed and classified.

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

Describe the primary objects in PP basic data Explain the SAP definition of each PP basic data element Identify the PP organizational units Describe how to use document management and classification functions Navigate the PP menu paths

Unit Contents Lesson: Overview of PP Basic Data ................................................ 2 Lesson: Organizational Levels and Master Data in Production.................. 5

2003/Q2

© 2004 SAP AG. All rights reserved.

1

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

Lesson: Overview of PP Basic Data Lesson Overview This lesson provides an overview of integrating and using PP basic data.

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

Describe the primary objects in PP basic data Explain the SAP definition of each PP basic data element

Business Example As a member of the project team in a company that manufactures pumps, you are responsible for the introduction of basic data. The defined basic data will be used in the procurement, scheduling and costing of all components and products necessary for the manufacturing of pumps.

Description of PP Basic Data PP basic data is required for product costing and for punctual procurement of products. Before you can enter basic data, you must have created organizational units and a plant. 1. 2. 3.

2

You can then create material masters for all materials that are used or produced in the plant. Once you have created material masters with plant data, you can create BOMs and routings for a product. Define work centers for the plant. (They form the basis for operations in the routing.)

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Overview of PP Basic Data

Figure 1: Using PP Basic Data

2003/Q2

© 2004 SAP AG. All rights reserved.

3

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

Lesson Summary You should now be able to: • Describe the primary objects in PP basic data • Explain the SAP definition of each PP basic data element

4

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Organizational Levels and Master Data in Production

Lesson: Organizational Levels and Master Data in Production Lesson Overview This lesson covers the organizational levels and introduces you to document usage and classification.

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

Identify the PP organizational units Describe how to use document management and classification functions Navigate the PP menu paths

Business Example As a member of the project team, you must understand how PP basic data and master data are used.

Organizational Levels and Material Master Some material data is valid on all organizational levels, and other data is only valid for specific levels. The material master is arranged to allow material data to be managed centrally within the company. This prevents datasets from being unecessarily filled with redundant information. The material master reflects the structure of a company. The figure shows the structure of the material master record.

2003/Q2

© 2004 SAP AG. All rights reserved.

5

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

Figure 2: Organizational Levels for the Material Master Record

You can save data at different company levels: • • •

Client level Plant level Storage location level

General material data that applies to the whole company is stored at the client level. Examples of this kind of data are material short texts, base units of measure and conversion factors for alternative units of measure. All data that applies to a plant and its assigned storage locations is stored at the plant level. An example of this type of data is work scheduling data. Production planning and execution take place at plant level. All data that applies to a specific storage location is stored at the storage location level. This data is mainly storage location stock. A plant is an organizational unit within a company. A plant is a place where valued goods and services are: • • • •

6

Produced Stored Consumed Distributed

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Organizational Levels and Master Data in Production

Examples of plants include factories, central warehouses, corporate headquarters and sales offices. Basic data is used to: • • • • •

Determine materials staging Determine production methods with operation dates for an order Calculate start and finish dates for an order Identify available capacity and expected usage Calculate product and production costs

PP basic data: • • • • • •

Material BOM Routing Work center Production resources/tools Documents

Figure 3: Basic Data and Basic Functions

In manufacturing, everything revolves around material masters and BOMs, which determine the relationships between the materials used in production. Material masters must exist before a bill of material and its components can be created.

2003/Q2

© 2004 SAP AG. All rights reserved.

7

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

Bills of materials indicate what materials are used to produce a product. The components in a BOM can be assigned to specific operations where they are required. Work centers must be defined before they can be used in an operation. Production resources and tools identify the tools needed to do the work. They can be assigned to operations. Documents created in document management can be assigned as components in BOMs, or as a PRT to routing operations. Standard R/3 texts can be created and assigned to PP basic data objects. The R/3 classification system can be used to group PP basic data according to user-defined attributes.

Figure 4: Routing Usage

A routing shows operations in a sequence and acts as a template for production orders. The planned time for each operation is stored in the routing as standard values. These standard values are the basis for: • • •

8

Lead time scheduling Product costing Capacity planning

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Organizational Levels and Master Data in Production

Figure 5: Master Data in Production Orders

For the material you want to produce, you must set the procurement type to in-house production (X,E). You must maintain at least one plant-specific view (MRP and/or work scheduling) and the accounting and costing views for the material. You must create BOMs as single-level BOMs. Create routings as routings (generic).

Figure 6: Material Master Views

2003/Q2

© 2004 SAP AG. All rights reserved.

9

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

The material master is used by all SAP R/3 logistics applications. It controls whether a material is purchased, produced or sold. Every area of responsibility can have a material master view. Because different user departments in a company work with the same material, and each of these departments wants to store different information on the material, you can subdivide material master data according to the department it belongs to. Each department has its own material master record view and is responsible for its data being correct. The data that you maintain in the following views is used by PP functions: • • • •

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

BOM BOMs contain the materials used to produce a product. BOMs contain assemblies and components that flow into the production of a material. The figure shows the BOM for a pump.

10

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Organizational Levels and Master Data in Production

Figure 7: Sample BOM: Pump

BOMs are used in material requirements planning, production, procurement and product costing. A BOM consists of a BOM header and BOM items. The base quantity in the header specifies the finished product quantity the item quantities are based on. BOM items indicate individual parts and assemblies, which are identified by their material numbers. BOMs are single level. A BOM item can also contain components, so that a multi-level production can be described by the single-level BOMs from the finished product, assemblies or assemblies of the assemblies (and so on). In addition to stock items, which flow into the finished product, a BOM can also contain documents or text items.

Work Centers, Routings, Production Resources/Tools and Document Usage A work center is a location that defines when and where production resources are required according to order requirements. In different companies, work centers are also called machine centers or capacity centers.

2003/Q2

© 2004 SAP AG. All rights reserved.

11

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

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

Figure 8: Work Center

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

12

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

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Organizational Levels and Master Data in Production

Figure 9: Routing

Production resources and tools (PRTs) are items that are used but not necessarily consumed during production. In SAP R/3 there are different types of production resources and tools to differentiate between different purposes. • • • •

2003/Q2

Production resources and tools with material master Production resources and tools with document master Production resources and tools with equipment master Miscellaneous production resources and tools

© 2004 SAP AG. All rights reserved.

13

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

Figure 10: Description of Production Resources and Tools

Documents are basic data that can be used system-wide or on an individual basis depending on the document type. They can be linked to operations as PRTs or to a BOM using the item category. Documents are defined separately in the document management system. Documents can be specified as a component in a BOM or as a PRT document. If they are used as a PRT, they are assigned to an operation in a routing.

14

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Organizational Levels and Master Data in Production

Figure 11: Document Usage

You define user authorizations for the document types in PP basic data in Customizing for the document management system.

Classification Classification supports the user-defined relationships among different objects in SAP R/3. Classification allows you to search for individual objects or groups of objects with similar values.

2003/Q2

© 2004 SAP AG. All rights reserved.

15

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

Figure 12: Classification System

The purpose of classification is: • • •

To enable you to find objects To enable you to find similar objects To establish that no object matching a set of user-defined criteria exists

A prerequisite for these requirements is an appropriate classification system. The SAP classification system allows you to use matchcodes and mnemonic numbers to build such a classification system. The four parts of the classification system are: • • • •

16

Characteristics maintenance Class maintenance Classification (assignments) Object search

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Organizational Levels and Master Data in Production

Figure 13: Classification System Functions

An object is a unit that can be classified (such as material, supplier, work center and so on). A class is a name for a group of objects that have the same or similar attributes. A characteristic describes specifications of an object (such as length, standard, basic material and so on). A characteristic value gives an exact value for the characteristic (for example, 10cm, DIN 931, iron and so on). Procedure for class maintenance: 1. 2. 3. 4.

2003/Q2

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

© 2004 SAP AG. All rights reserved.

17

Unit 1: Overview of Organizational Structures & PP Basic Data

PLM111

Lesson Summary You should now be able to: • Identify the PP organizational units • Describe how to use document management and classification functions • Navigate the PP menu paths

Related Information Course PLM130 contains more information on the SAP classification system.

18

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Unit Summary

Unit Summary You should now be able to: • Describe the primary objects in PP basic data • Explain the SAP definition of each PP basic data element • Identify the PP organizational units • Describe how to use document management and classification functions • Navigate the PP menu paths

2003/Q2

© 2004 SAP AG. All rights reserved.

19

Unit Summary

20

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Test Your Knowledge

Test Your Knowledge

2003/Q2

1.

What are routings used for?

2.

Name the four focus types of production resources and tools.

© 2004 SAP AG. All rights reserved.

21

Test Your Knowledge

PLM111

Answers 1.

What are routings used for? Answer: Routings are used as scheduling and costing templates. They also serve as copy templates for production orders.

2.

Name the four focus types of production resources and tools. Answer: The four types of production resources and tools are production resources and tools with material master, miscellaneous production resources and tools, production resources and tools with document master, and production resources and tools with equipment master.

22

© 2004 SAP AG. All rights reserved.

2003/Q2

Unit 2 Displaying Routings Unit Overview This unit covers the routing structure and routing types.

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

Navigate through the routing and display all views

Unit Contents Lesson: Routing Structure and Routing Types................................... 24 Exercise 1: Routing Structure and Routing Types .......................... 27

2003/Q2

© 2004 SAP AG. All rights reserved.

23

Unit 2: Displaying Routings

PLM111

Lesson: Routing Structure and Routing Types Lesson Overview This unit explains the simplest way to display a routing and describes the process of the necessary work center maintenance.

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

Navigate through the routing and display all views

Business Example You want an get an overview of the production methods for a pump and display the routing for this pump.

Routing Structure In SAP R/3, routings are used to support various business functions. (For example?) You can also store more than one routing, including operations, for manufacturing a material in a routing structure.

Figure 14: Routing structure

24

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Routing Structure and Routing Types

A routing determines the sequence of individual operations that are necessary to produce a finished product. A routing contains operations and information about the work centers where the individual operations are carried out and about the standard times. Other important information included in the routing refers to the material components required for an operation as well as the necessary tools, jigs and fixtures (production resources/tools). If you want inspections to be carried out during an operation, you can assign inspection characteristics to the operation in a routing. The characteristic overview is the starting point for assigning an inspection characteristic. You can assign trigger points to operations in routings, so that later in the production order, certain functions are triggered when certain events occur. Such an event could be a specific confirmation from an operation.

Figure 15: Routing

You can combine routings with similar production cycles in a task list group. An alternative sequence additionally allows you to select alternative operations for a sequence of operations. This could be the case when using different work procedures for various lot sizes or when working around capacity bottlenecks. A parallel sequence allows you to process operations concurrently with others. The processing sequence is defined by the branch and return operations.

2003/Q2

© 2004 SAP AG. All rights reserved.

25

Unit 2: Displaying Routings

PLM111

Task List Types

Figure 16: Task list types

The task list types are assigned to the different applications. A standard routing describes material-related production in production planning. A reference operation set is not material-specific . Reference operation sets can be used as references and as templates for standard routings. A rate routing describes material-related production within a production line and is used mostly in repetitive manufacturing. A reference rate routing helps you create rate routings. Master recipes are used in the process industry. Rough-cut planning profiles are used in Sales and Operation Planning. Standard networks are network structures that are independent of any particular project and that can be used as a template in the creation of operative networks. Using standard networks to create networks can save time if different projects have the same operations. An inspection plan is used for carrying out quality inspections and for measures that are relevant to production, such as goods inspection on receipt.

26

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Routing Structure and Routing Types

Exercise 1: Routing Structure and Routing Types Exercise Objectives After completing this exercise, you will be able to: • Display a standard routing

Business Example You are responsible for the routing description of an assembly and of a pump.

Task 1: Display a standard routing. 1.

Select Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display. Display the standard routing for pump T-F1## in plant 1000. What are the task list group number and group counter?

2.

When was the routing created and by whom? What are the effectivity dates for the routing? ______________________________________

3.

What are the effectivity dates for operation 30? Go to the operations overview. ______________________________________

4.

What are the standard values for operation 30?

Task 2: Display the object overview for the routing.

2003/Q2

1.

Display the object overview for the routing for pump T-F1##. Choose the overview variant (variant 4) for displaying the routing, sequence, operation, material, production resources/tools, and characteristics. How many sequences does the routing have?

2.

Are material components assigned to an operation?

3.

To which operations are production resources/tools assigned?

© 2004 SAP AG. All rights reserved.

27

Unit 2: Displaying Routings

PLM111

Solution 1: Routing Structure and Routing Types Task 1: Display a standard routing. 1.

Select Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display. Display the standard routing for pump T-F1## in plant 1000. What are the task list group number and group counter? a)

b) 2.

Enter the following: Field

Entry

Material

T-F1##

Plant

1000

Select Header. This is where you can read the task list group number and the group counter.

When was the routing created and by whom? What are the effectivity dates for the routing? ______________________________________ a) b)

3.

Scroll down to the administrative data. You can also find the effectivity data in the administrative data.

What are the effectivity dates for operation 30? Go to the operations overview. ______________________________________ a)

4.

Click Operations to access the operation overview. Select the operation details by double-clicking operation 30. Scroll down to the administrative data for the operation.

What are the standard values for operation 30? a)

Scroll back up to the standard values for the operation. Setup time: 15 minutes; machine and labor times: 10 minutes each.

Continued on next page

28

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Routing Structure and Routing Types

Task 2: Display the object overview for the routing. 1.

Display the object overview for the routing for pump T-F1##. Choose the overview variant (variant 4) for displaying the routing, sequence, operation, material, production resources/tools, and characteristics. How many sequences does the routing have? a) b)

Select Goto → Object overview. Select variant 4 of the overview variants. Sequence 0 (standard sequence)

2.

Are material components assigned to an operation? a)

3.

To which operations are production resources/tools assigned? a)

2003/Q2

No Operations 20 and 50 have production resources/tools assigned to them.

© 2004 SAP AG. All rights reserved.

29

Unit 2: Displaying Routings

PLM111

Lesson Summary You should now be able to: • Navigate through the routing and display all views

30

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Unit Summary

Unit Summary You should now be able to: • Navigate through the routing and display all views

2003/Q2

© 2004 SAP AG. All rights reserved.

31

Unit Summary

32

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Test Your Knowledge

Test Your Knowledge 1.

2003/Q2

Which function does the task list group have?

© 2004 SAP AG. All rights reserved.

33

Test Your Knowledge

PLM111

Answers 1.

Which function does the task list group have? Answer: The task list group defines the person responsible for scheduling the work. (not mentioned in lesson!)

34

© 2004 SAP AG. All rights reserved.

2003/Q2

Unit 3 Work Center Unit Overview This unit covers work center data from the aspect of work scheduling. This unit describes how to create a work center and explains default values for operations, the work center hierarchy and reporting programs.

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

Identify which work center data is relevant for routings Create reports for work centers and make mass changes

Unit Contents Lesson: Work Center Data, Default Data, Work Center Hierarchy............ 36 Exercise 2: Work Center Data, Default Data, Work Center Hierarchy ... 43 Lesson: Reporting and Mass Changes ........................................... 53

2003/Q2

© 2004 SAP AG. All rights reserved.

35

Unit 3: Work Center

PLM111

Lesson: Work Center Data, Default Data, Work Center Hierarchy Lesson Overview This unit deals only with the work center data that is relevant with respect to a routing.

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

Identify which work center data is relevant for routings

Business Example • •

Your company wants to reorganize its work centers You are responsible for setting up and maintaining the work centers.

Work Center Data Similar to the material master, the work center is made up of several subscreens. The work center is plant-specific and can be used in routings. However, for production orders, it is mandatory to assign cost centers and activity types.

36

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Data, Default Data, Work Center Hierarchy

Figure 17: Work center

Work centers determine the place where the operation is to be executed. They contain • • •

2003/Q2

Contain default values that are copied or referenced in operations when you create routings Costing data that enable the costing of operations Scheduling and capacity data required for lead time scheduling and capacity planning

© 2004 SAP AG. All rights reserved.

37

Unit 3: Work Center

PLM111

Figure 18: Work center data

A work center contains several groups of data that you can enter on various screens (tab pages). Default values are copied to the routing. You use the reference indicator to specify whether a default value can be changed in the routing.

Default values The work center contains default values that are copied when you create an operation and that can be changed in the operation, if necessary. However, if the default values are marked as a reference in the work center, then you cannot make a change in the operation. The default values for work center maintenance are stored in Customizing per plant for the order type.

38

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Data, Default Data, Work Center Hierarchy

Figure 19: Default values in work centers

Note: When setting up an SAP R/3 PP system, you should make sure that as much data as possible is defined in work center maintenance. The default values are copied to routings or production orders. This data is saved partly in various screens in the work center. Activity types are proposed from the cost center assignment screen. Standard texts for operation descriptions can be predefined in SAP R/3.

2003/Q2

© 2004 SAP AG. All rights reserved.

39

Unit 3: Work Center

PLM111

Figure 20: Standard text for operation description

To maintain standard texts, choose Routings → Extras → Standard text. A standard text key identifies the standard text. You can specify this key in the work center. When you use the work center in a routing, the standard text is copied or referenced in the operation.

Costing For operation costing, it is necessary to assign the work center to a cost center. Additionally, activity types with cost unit rates are required because multiple work centers can belong to one cost center.

40

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Data, Default Data, Work Center Hierarchy

Figure 21: Production costing

You can assign a work center to only one cost center in a time period. A cost center can contain several work centers. You must enter the cost center activity types that are relevant to costing at a work center. There must be an activity type master for the activity types used. The activity types maintained in the work center are used as default values for the operation. If no reference indicator has been set for the activity type in the work center, you can change the activity type in the operation.

Work Center Hierarchy Work center hierarchies serve to aggregate available capacities and capacity requirements in capacity planning. You can assign the work center to work center hierarchies for reporting. A work center can be assigned to multiple hierarchies.

2003/Q2

© 2004 SAP AG. All rights reserved.

41

Unit 3: Work Center

PLM111

Figure 22: Work center hierarchy

Work centers can be arranged in work center hierarchies. A hierarchy can consist of any number of levels.

42

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Data, Default Data, Work Center Hierarchy

Exercise 2: Work Center Data, Default Data, Work Center Hierarchy Exercise Objectives After completing this exercise, you will be able to: • Create a standard text • Create and change a work center

Business Example Two new machines have been purchased to support the assembly process for the new pump. You are responsible for the definition of a new work center that represents the two new machines.

Task 1: Define a standard text for the operation description as the standard text for the new work center. 1.

Create a standard text key T## with the description Assembly instructions for group ##. Enter Complete the pump assembly as the long text.

Task 2: Create a work center. 1.

Create work center CENTER## in plant 1000. The work center is intended for the two identical new machines with the work center category 0003. Hint: To maintain the individual tab pages (screen sequences), select Next screen.

2.

Maintain the following data on the Basic data tab page: Field

Entry

Description

Pump assembly ##

Person responsible

0## Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

43

Unit 3: Work Center

PLM111

Field

Entry

Usage

All task list types

Standard value key

Normal production

Rules for maintenance

Setup time - should be entered Machine time - must be entered Labor time - is not checked

Performance efficiency rate key 3.

Machine - 090 %

On the Default values tab page, choose the control key (between PP01 and PP99), your standard text key, and minutes as the unit of measure. Set the reference indicator for the control key. Note: Choose a control key from the PP series (P01 to PP99). It must allow scheduling, capacity planning, and costing. It must also print time tickets and allow confirmations.

4.

Save the work center.

Continued on next page

44

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Data, Default Data, Work Center Hierarchy

Task 3: Answer the following questions about the work center that you have just saved. 1.

Can you define operations using this work center without entering a setup time?

2.

Can you use a work center, in which only the basic data and default values tab pages have been defined, in routing operations?

Task 4: Add data for capacity, scheduling, and costing to the work center CENTER##. To do so, use the change transaction and the work center check function. 1.

2.

Enter the capacity category 001 and on theChange Work Center Capacity: Header screen, adjust the capacity data using the following capacity data: Field

Entry

Capacity planner group

0##

Grouping

51

Base unit of measure

Hour

Start/finish time

08:00 / 17:00

Length of breaks

1 hour

Capacity utilization

80 %

Number of individual capacities

2 machines

Maintain the following data on the Scheduling tab page:

Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

45

Unit 3: Work Center

PLM111

Field

Entry

Scheduling basis: Capacity category

001

Formulas for setup/processing

SAP001 / SAP002

Location group

0002

Standard queue time

2 hours

3.

Why is the assignment of a capacity category in the scheduling view important?

4.

What is determined with the help of the location group?

5.

Maintain the following data on the Costing tab page: Cost center Activity type

4230 Setup time -1422 Machine time -1420

Formula keys

Setup - SAP005 Machine - SAP006

Continued on next page

46

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

2003/Q2

Lesson: Work Center Data, Default Data, Work Center Hierarchy

6.

Why is the activity type so important?

7.

Complete the addition of the data for work center CENTER##.

© 2004 SAP AG. All rights reserved.

47

Unit 3: Work Center

PLM111

Solution 2: Work Center Data, Default Data, Work Center Hierarchy Task 1: Define a standard text for the operation description as the standard text for the new work center. 1.

Create a standard text key T## with the description Assembly instructions for group ##. Enter Complete the pump assembly as the long text. a) b)

Select Logistics → Production → Master Data → Work Centers → Extras → Standard texts: Task List. Make the required entries.

Task 2: Create a work center. 1.

Create work center CENTER## in plant 1000. The work center is intended for the two identical new machines with the work center category 0003. Hint: To maintain the individual tab pages (screen sequences), select Next screen. a) b) c)

2.

Select Logistics → Production → Master Data → Work Centers → Work Center → Create. Enter plant 1000, work center number CENTER##, and work center category 0003. Select Enter.

Maintain the following data on the Basic data tab page: Field

Entry

Description

Pump assembly ##

Person responsible

0##

Usage

All task list types

Continued on next page

48

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Data, Default Data, Work Center Hierarchy

Field

Entry

Standard value key

Normal production

Rules for maintenance

Setup time - should be entered Machine time - must be entered Labor time - is not checked

Performance efficiency rate key a)

Machine - 090 %

After the work center number, enter the work center description Pump assembly ##. Use the input help to enter the person responsible, usage, and standard value key. Press Enter to be able to enter the rules for maintenance and the key for performance efficiency rate.

3.

On the Default values tab page, choose the control key (between PP01 and PP99), your standard text key, and minutes as the unit of measure. Set the reference indicator for the control key. Note: Choose a control key from the PP series (P01 to PP99). It must allow scheduling, capacity planning, and costing. It must also print time tickets and allow confirmations. a) b)

Select Next screen. Maintain the following data on the Default values tab page: Field

Entry

Control key

PP01to PP99

Standard text key

T##

Unit of measure for standard Minute values Reference indicator 4.

For the control key

Save the work center. a)

Select Save. Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

49

Unit 3: Work Center

PLM111

Task 3: Answer the following questions about the work center that you have just saved. 1.

Can you define operations using this work center without entering a setup time? Answer: Yes, but a warning message appears that prompts you to enter a setup time.

2.

Can you use a work center, in which only the basic data and default values tab pages have been defined, in routing operations? Answer: In the routing, yes. In the production order, no.

Task 4: Add data for capacity, scheduling, and costing to the work center CENTER##. To do so, use the change transaction and the work center check function. 1.

Enter the capacity category 001 and on theChange Work Center Capacity: Header screen, adjust the capacity data using the following capacity data: Field

Entry

Capacity planner group

0##

Grouping

51

Base unit of measure

Hour

Start/finish time

08:00 / 17:00

Length of breaks

1 hour

Capacity utilization

80 %

Number of individual capacities

2 machines

a) b) 2.

Select Logistics → Production → Master Data → Work Centers → Work Center → Change + Work Center → Check. To access the capacity header data, double-click the number of the capacity category, or click Capacity header data.

Maintain the following data on the Scheduling tab page:

Continued on next page

50

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Data, Default Data, Work Center Hierarchy

Field

Entry

Scheduling basis: Capacity category

001

Formulas for setup/processing

SAP001 / SAP002

Location group

0002

Standard queue time

2 hours

a) 3.

Select Back and Next screen.

Why is the assignment of a capacity category in the scheduling view important? Answer: The scheduling basis defines which data is used to calculate lead time scheduling. For example, the machine capacity category defines which days are working days and that this work center is available each working day between 8:00 AM and 5:00 PM.

4.

What is determined with the help of the location group? Answer: Move time. The actual move time value is defined in a move time matrix. The actual move time is the value for the location group of a work center in an operation with relation to the location group for the work center in the next operation of a routing.

5.

Maintain the following data on the Costing tab page: Cost center

4230

Activity type

Setup time -1422 Machine time -1420

Formula keys

Setup - SAP005 Machine - SAP006

a) 6.

Make the required entries.

Why is the activity type so important? Answer: The activity type contains the cost center’s price for each activity that is to be performed in the work center.

7.

Complete the addition of the data for work center CENTER##. a)

2003/Q2

Select Save.

© 2004 SAP AG. All rights reserved.

51

Unit 3: Work Center

PLM111

Lesson Summary You should now be able to: • Identify which work center data is relevant for routings

Related Information The data relevant to capacity is discussed in course SCM360 – Capacity Planning.

52

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Reporting and Mass Changes

Lesson: Reporting and Mass Changes Lesson Overview This lesson deals with the work center data that is relevant with respect to a routing.

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

Create reports for work centers and make mass changes

Business Example You want to find out where the work center is used and make mass changes to the data contents, if necessary.

Reporting and Mass Change Text missing

Figure 23: Reports regarding work centers and capacities

2003/Q2

© 2004 SAP AG. All rights reserved.

53

Unit 3: Work Center

PLM111

Lesson Summary You should now be able to: • Create reports for work centers and make mass changes

Related Information The data relevant to capacity is discussed in course SCM360 – Capacity Planning.

54

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Unit Summary

Unit Summary You should now be able to: • Identify which work center data is relevant for routings • Create reports for work centers and make mass changes

2003/Q2

© 2004 SAP AG. All rights reserved.

55

Unit Summary

56

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Test Your Knowledge

Test Your Knowledge 1.

Can a work center for which only the basic data view has been maintained be used in an operation of a routing? Choose the correct answer(s).

□ □ □ □

2003/Q2

A B C D

Yes, without any problems Yes, but you must enter the control key into the operation manually. No, it can't.

© 2004 SAP AG. All rights reserved.

57

Test Your Knowledge

PLM111

Answers 1.

Can a work center for which only the basic data view has been maintained be used in an operation of a routing? Answer: B

58

© 2004 SAP AG. All rights reserved.

2003/Q2

Unit 4 Creating a Routing Unit Overview This unit covers creating and changing routings. It demonstrates how to use the Engineering Workbench to make enhancements.

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

Expand routings using the Engineering Workbench Assign material components to operations Maintain variable-size items with cutting measures Maintain and use production resources/tools

Unit Contents Lesson: Structure of the Engineering Workbench Interface.................... 60 Lesson: Creating a Routing and Material Assignment .......................... 65 Lesson: Production Resources/Tools ............................................. 68 Exercise 3: Creating a Routing, Material Assignment ...................... 71

2003/Q2

© 2004 SAP AG. All rights reserved.

59

Unit 4: Creating a Routing

PLM111

Lesson: Structure of the Engineering Workbench Interface Lesson Overview This lesson explains how to use the Engineering Workbench to create and change routings and provides additional information.

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

Expand routings using the Engineering Workbench

Business Example Because you are responsible for maintaining routings in the project team, you want to know how to create and change routings using the Engineering Workbench.

Worklist and Screen Layout The Engineering Workbench is a maintenance environment for product structures and PP objects; its capabilities far exceed those of the conventional maintenance of BOMs and routings. You do not have to process routings and BOMs separately. The most important objects of the Engineering Workbench are BOM items and operations. Views are applied to these objects, which then further enable the conventional BOM or routing structures to be used. These views support the full extent of the processing functions, such as: • • • •

Creating Changing Displaying Deleting

The worklist contains the selected objects, so that they can be displayed, changed or newly created in the Engineering Workbench. The system copies these objects from the database into the worklist. Only when the worklist has been saved following the processing of objects, are new objects created in the database or existing ones changed or deleted.

60

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Structure of the Engineering Workbench Interface

Figure 24: Worklist: Use

The screen of the Engineering Workbench is divided in three sections: • • •

Toolbar Cockpit Overview

Figure 25: Screen layout

2003/Q2

© 2004 SAP AG. All rights reserved.

61

Unit 4: Creating a Routing

PLM111

The toolbar provides the user with currently available functions that are represented by icons. The cockpit controls the Engineering Workbench. It is always available and consists of three sections: Process using This section is where you enter a key date or a change number to process the objects in the worklist. You need to enter a key date or a change number when you add, change, or delete an object. Effectivity window This section is where you can display a particular time segment of the worklist. Context This section is where the hierarchical relationships of objects in the overview screen are displayed. This screen contains one input line each for material, BOM and item. The overview lists objects that are contained in the worklist and that match the entries in the effectivity window and in the context. It provides information about the objects and change statuses of a particular object type.

Origin of the Default Values The default values from the work center can be references. You can also specify maintenance rules for standard values in a routing. You can specify default values in a profile for each routing usage. Only in a routing can the reference indicator protect from overwriting.

62

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Structure of the Engineering Workbench Interface

Figure 26: Origin of default values in routings

2003/Q2

© 2004 SAP AG. All rights reserved.

63

Unit 4: Creating a Routing

PLM111

Lesson Summary You should now be able to: • Expand routings using the Engineering Workbench

64

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Creating a Routing and Material Assignment

Lesson: Creating a Routing and Material Assignment Lesson Overview In this lesson, you will learn how to assign materials to a routing.

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

Assign material components to operations Maintain variable-size items with cutting measures

Business Example You are responsible for the correct staging of material components for the operation. Therefore you have to assign these components to operations and, if necessary, adjust the BOMs.

Material Assignment Material components must be assigned to operations.

Figure 27: Material assignment

2003/Q2

© 2004 SAP AG. All rights reserved.

65

Unit 4: Creating a Routing

PLM111

You can assign and display material components for separate operations in the material component overview. For a clearer overview, you can use different criteria to filter or sort the material component list. You can • • •

Assign a new component Delete and reassign material assignments Navigate between multiple operations

You can maintain BOMs completely without having to leave routing maintenance.

Figure 28: Assigning a variable-size item

When you maintain the BOM, the final measurements are specified for the variable-size items. If you require a large cutting measure for the production of this BOM item, you can specify this when you assign the operation. Only those involved in material staging get these measurements. Inventory management books out the measurements from the BOM.

66

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Creating a Routing and Material Assignment

Lesson Summary You should now be able to: • Assign material components to operations • Maintain variable-size items with cutting measures

2003/Q2

© 2004 SAP AG. All rights reserved.

67

Unit 4: Creating a Routing

PLM111

Lesson: Production Resources/Tools Lesson Overview This lesson explains how to create and use production resources/tools.

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

Maintain and use production resources/tools

Business Example why use production resources/tools

Production Resources/Tools Production resources/tools are required to carry out an operation and therefore have to be assigned to that operation. The PRT must be identified by a material master or a PRT master. The input screen for production resources/tools with a material master is automatically displayed when assigning a PRT to an operation. The PRT category can be changed.

Figure 29: Production Resources/Tools

In the SAP system, you can assign various PRT categories to an operation in a routing or a production order. The PRT category is determined by the requirements of a PRT and its reference to a particular object (material, equipment, and so on).

68

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Production Resources/Tools

Figure 30: Comparison of PRT Categories

2003/Q2

© 2004 SAP AG. All rights reserved.

69

Unit 4: Creating a Routing

70

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Production Resources/Tools

Exercise 3: Creating a Routing, Material Assignment Exercise Objectives After completing this exercise, you will be able to: • Create a simple routing with the Engineering Workbench • Enter a BOM item, and assign an operation • Use production resources/tools

Business Example You are responsible for the maintenance of master data for routings and BOMs in your company; to do this, you use the common maintenance interface in the Engineering Workbench.

Task 1: Create three material masters using templates. 1.

For both material T-F## and TP-F##, create a material master for the material type Finished Product, and for the industry sector Mechanical Engineering by using the template T-F1##. Select Logistics → Production → Master Data → Material Master → Material → Create (Special) → Finished Product.

2.

Maintain the Work Scheduling view for plant 1000. The description for T-F## should be Pump 1##, and Pump 2## for TP-F##.

3.

Create a material master for the material T-B## with material type Semifinished Product, and for the Mechanical Engineering industry sector, use template 400-431. Select Logistics → Production → Master Data → Material Master → Material → Create (Special) → Semifinished Product.

4.

Maintain the Work Scheduling view for plant 1000. The description for T-B## should read Washer ##. In the Production scheduler field, enter your 3-digit group number.

Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

71

Unit 4: Creating a Routing

PLM111

Task 2: Call the transaction for the Engineering Workbench. 1.

In the EWB, select P_ALLES as the current working area, and save it as the default working area.

Task 3: Create a standard routing. 1.

Create a routing for the production of a washer with material number T-B## in plant 1000. The routing should be valid immediately and used for a lot size of 1-1000 pieces.

2.

Enter the operations specified in the following table into your routing, and either copy the operation texts from the standard text keys from the work center, or enter them manually. Op.

Work Center

Operation Description

Setup Time

10

1121

Copy default text

1 min.

20

1320

Punch holes with tool

2 min.

30

1721

Copy default text

Mach. Time

Labor Time 1 min.

3 min.

3 min. 2 min.

Task 4: Create a BOM with one component. 1.

You need a cork insert for the production of washer T-B##. Create a BOM with a block of cork as a component. First create a BOM header. The BOM should be used for production and set as active.

2.

Create BOM item 10 with item category R and material number T-T##. Because a material master record does not yet exists for this block of cork, a dialog box appears to maintain the material master record.

3.

Maintain only the MRP 1 view with the MRP profile PD01 and the data from the table below. After you confirm the entries, you return to the Engineering Workbench where you specify the variable-size item data.

Continued on next page

72

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Production Resources/Tools

Field

Entry

Industry Sector

Mechanical Engineering

Material Type

Raw Material

Description

Cork block ##

Base unit of measure

m2

4.

The engineering department specifies the final measurements for the washer BOM item as being 60 x 60 mm per piece. (What needs to be done?)

5.

You are the industrial engineer, and you want to punch the washer with a tool and therefore need a larger cutting measure than specified by engineering. Assign the component to operation 20, and enter the cutting measures 80 x 80 mm for the cutting measure. Save the data. Hint: For MRP and inventory management, only the measurements from the BOM are valid.

2003/Q2

6.

Assign the miscellaneous production resource/tool PP-FHMS to operation 20.

7.

Check the assignments in the operations overview. Save the changes and exit the Engineering Workbench.

© 2004 SAP AG. All rights reserved.

73

Unit 4: Creating a Routing

PLM111

Solution 3: Creating a Routing, Material Assignment Task 1: Create three material masters using templates. 1.

For both material T-F## and TP-F##, create a material master for the material type Finished Product, and for the industry sector Mechanical Engineering by using the template T-F1##. Select Logistics → Production → Master Data → Material Master → Material → Create (Special) → Finished Product. a) b)

2.

Maintain the Work Scheduling view for plant 1000. The description for T-F## should be Pump 1##, and Pump 2## for TP-F##. a)

3.

Select the Mechanical Engineering industry sector. Enter T-F1## as the Copy From material. On the Select View(s) screen, choose Work Scheduling. Enter plant 1000 twice on the Organizational Levels screen. Change the material description in the Work Scheduling view, and note the correct production scheduler number.

Make the required entries.

Create a material master for the material T-B## with material type Semifinished Product, and for the Mechanical Engineering industry sector, use template 400-431. Select Logistics → Production → Master Data → Material Master → Material → Create (Special) → Semifinished Product. a)

4.

Make the required entries.

Maintain the Work Scheduling view for plant 1000. The description for T-B## should read Washer ##. In the Production scheduler field, enter your 3-digit group number. a)

Make the required entries.

Continued on next page

74

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Production Resources/Tools

Task 2: Call the transaction for the Engineering Workbench. 1.

In the EWB, select P_ALLES as the current working area, and save it as the default working area. a) b)

Select Logistics → Production → Master Data → Engineering Workbench. Select P_ALLES from the list as the current working area. Click the Save as default icon in front of Current working area to make it the default and click enter to continue. ..

Task 3: Create a standard routing. 1.

Create a routing for the production of a washer with material number T-B## in plant 1000. The routing should be valid immediately and used for a lot size of 1-1000 pieces. a) b) c)

2.

Enter only the material number T-B## and select Execute . Load routings and BOMs. Then click Create. Create the header. Enter plant 1000 and routing type N in the context block. Confirm the dialog box for valid from current date, and enter the lot size 1 to 1000 pieces on the Headers general tab page.

Enter the operations specified in the following table into your routing, and either copy the operation texts from the standard text keys from the work center, or enter them manually. Op.

Work Center

Operation Description

Setup Time

10

1121

Copy default text

1 min.

20

1320

Punch holes with tool

2 min.

30

1721

Copy default text

a) b)

Mach. Time

Labor Time 1 min.

3 min.

3 min. 2 min.

Double-click the O column (for Operations). To enter the processing times, switch to the corresponding tab page. Save the routing. Do not exit the Engineering Workbench.

Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

75

Unit 4: Creating a Routing

PLM111

Task 4: Create a BOM with one component. 1.

You need a cork insert for the production of washer T-B##. Create a BOM with a block of cork as a component. First create a BOM header. The BOM should be used for production and set as active. a) b)

2.

Create BOM item 10 with item category R and material number T-T##. Because a material master record does not yet exists for this block of cork, a dialog box appears to maintain the material master record. a)

3.

Select Bills of Material → Items. Enter the item category R and the material number T-T##.

Maintain only the MRP 1 view with the MRP profile PD01 and the data from the table below. After you confirm the entries, you return to the Engineering Workbench where you specify the variable-size item data. Field

Entry

Industry Sector

Mechanical Engineering

Material Type

Raw Material

Description

Cork block ##

Base unit of measure

m2

a) b) c)

4.

Create a BOM for your material T-B##. Use the menu path Bills of Material → BOM headers. Enter material T-B##, plant 1000, usage 1, and click Create. Enter BOM status 01 and click enter.

In the dialog box for creating material, enter the industry sector and the material type. Choose the MRP 1 view in the material master. In the Organizational Levels dialog box, enter the MRP profile PD01. Maintain only the description "cork block ##" and the base unit of measure m2. When you save the material master for the cork block, you return to BOM maintenance.

The engineering department specifies the final measurements for the washer BOM item as being 60 x 60 mm per piece. (What needs to be done?) a)

BOM item. On the Variable-size item tab page, enter the measurements, including the unit of measure, and 1 as the number of variable-size items.

Continued on next page

76

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Production Resources/Tools

5.

You are the industrial engineer, and you want to punch the washer with a tool and therefore need a larger cutting measure than specified by engineering. Assign the component to operation 20, and enter the cutting measures 80 x 80 mm for the cutting measure. Save the data. Hint: For MRP and inventory management, only the measurements from the BOM are valid. a)

To assign the BOM item, select Bill of Material → Component Allocations. Or To enter the cutting measures, scroll further to the right on the Component Assignment Overview.

b) c)

In the EWB: Options dialog box, choose application PP01. Enter the operation number for the item. Note: Instead, you can select the item and the operation by clicking the function name and the function name . Select Create component assignment on the toolbar.

6.

Assign the miscellaneous production resource/tool PP-FHMS to operation 20. a) b)

7.

Check the assignments in the operations overview. Save the changes and exit the Engineering Workbench. a)

2003/Q2

From the EWB, select the menu path Task Lists → Operations. Go to the Operations general tab page. To specify the production resource/tool, double-click the Pr column and choose the Miscellaneous tab page.

Select Task Lists → Operations to check the operations.

© 2004 SAP AG. All rights reserved.

77

Unit 4: Creating a Routing

PLM111

Lesson Summary You should now be able to: • Maintain and use production resources/tools

78

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Unit Summary

Unit Summary You should now be able to: • Expand routings using the Engineering Workbench • Assign material components to operations • Maintain variable-size items with cutting measures • Maintain and use production resources/tools

2003/Q2

© 2004 SAP AG. All rights reserved.

79

Unit Summary

80

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Test Your Knowledge

Test Your Knowledge 1.

2003/Q2

Can you create a routing without a material master?

© 2004 SAP AG. All rights reserved.

81

Test Your Knowledge

PLM111

Answers 1.

Can you create a routing without a material master? Answer: Yes, the routing is stored together with the task list group number and the associated group counter. However, the routing must be assigned to a material for production.

82

© 2004 SAP AG. All rights reserved.

2003/Q2

Unit 5 Engineering Workbench Unit Overview Unit Contents • •

Workbench objects: changing, copying and so on Working simultaneously in the EWB

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

Use the Engineering Workbench for extensive routing maintenance Use the EWB browser functions Select and use working areas

Unit Contents Lesson: Structure of the Engineering Workbench ............................... 84 Exercise 4: Using the EWB Browser.......................................... 91 Lesson: Using Different Working Areas and Selection Options ............... 97 Exercise 5: Selection Options ................................................ 105

2003/Q2

© 2004 SAP AG. All rights reserved.

83

Unit 5: Engineering Workbench

PLM111

Lesson: Structure of the Engineering Workbench Lesson Overview This lesson explains the structure of the Engineering Workbench and copy features. You will learn how to navigate in the Engineering Workbench and use the browser.

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

Use the Engineering Workbench for extensive routing maintenance Use the EWB browser functions

Business Example You would like to find the optimum maintenance environment for permanent changes which allows multiple users to make changes simultaneously. You would also like to create new master data and link it in a hierarchy.

Functions of the Engineering Workbench The Engineering Workbench is a tool for integrated processing of BOMs and routings. This means that both object types and their links are maintained simultaneously and in detail with the same user interface. Why the Engineering Workbench? • • • • • •

Support for complex planning processes Parallel processing Selecting specific objects from routings and BOMs Integrated processing of operations and items Setting targeted locks Representation of the development of change statuses

The concept of the Engineering Workbench however, goes far beyond the conventional maintenance of BOMs and routings. For example, all transactions for the conventional maintenance of these objects are brought together, and extensive change management is offered. If you use complex selection criteria, which can be combined in any way, the resulting data then contains no unwanted additional information – helping you to achieve and quick overview.

84

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Structure of the Engineering Workbench

The integration of an object browser as well as various viewers and the digital mockup viewer makes the workbench a central object within PLM.

Figure 31: Processing Objects Simultaneously

Any number of operations from any number of routings can be processed at the same time by different people. The same applies to different BOM items. If you want to process an operation that is already being processed by someone else, the Engineering Workbench gives you information to show you who to contact so that you can consult with the other processor. The processor can then release the operation (for example the BOM item) for you, without interrupting their work on other objects.

2003/Q2

© 2004 SAP AG. All rights reserved.

85

Unit 5: Engineering Workbench

PLM111

Structure of the Engineering Workbench

Figure 32: Structure of the Engineering Workbench

In order to display or process an individual object using the Engineering Workbench, you must select the corresponding object. Examples of objects are: • • • • •

The header of a routing The operation and suboperation The production resource/tool, trigger point and inspection characteristic The BOM header The item and subitem in the BOM

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

86

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Structure of the Engineering Workbench

Figure 33: Working Area 1

You do not have to process routings and BOMs separately. You simply choose the engineering object type, for example, material, operation and so on you want to work with. You group your choices together in a working area. The working area consists of the focus and the working environment. Focus The object type you use for selection. The focus also controls the input screen for the selection. Focus objects can be: Routing headers, operations, BOMs or items. Note: In the figure Working Area 1, the operation is the focus. Working environment Consists of the object types you want to display and process. All remaining object types in the working environment that have not been restricted by the working area can be contained in the Workbench. In the working area you determine which object types you are interested in. A working area can be specially adapted to particular requirements for processing, for example, for production or engineering/design. In the figure Working Area 2, the operation is the focus. The object types PRT, trigger point, inspection characteristic and subitem are excluded.

2003/Q2

© 2004 SAP AG. All rights reserved.

87

Unit 5: Engineering Workbench

PLM111

Figure 34: Working Area 2

You create the working areas in Customizing for the Engineering Workbench.

Figure 35: Choosing the Working Area

Using the Display working area function, you can specify a default working area or select another working area.

88

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Structure of the Engineering Workbench

In the dialog box Select working area you also have the option of going to the detail screen in the working area. In this detail screen you can display the information about the specified focus and about the object types contained in the working area.

2003/Q2

© 2004 SAP AG. All rights reserved.

89

Unit 5: Engineering Workbench

PLM111

90

2003/Q2

© 2004 SAP AG. All rights reserved.

PLM111

Lesson: Structure of the Engineering Workbench

Exercise 4: Using the EWB Browser Exercise Objectives After completing this exercise, you will be able to: • Create a routing and a BOM by using the Engineering Workbench to copy • Use the browser to copy and navigate an operation • Reassign component assignments

Business Example You are responsible for maintaining master data for BOMs and routings in your company; to do this you use the common maintenance interface in the Engineering Workbench.

Task 1: Complete an assignment using the Engineering Workbench. 1.

In the routing for the T-F2## pump with group counter 1, assign the flywheel to operation 20, and the hollow shaft to operation 40. Save the assignments, but do not exit the Engineering Workbench.

Task 2: Create a routing with BOM by copying multi-level. 1.

Now create a routing with BOM for the T-F## material with a lot size of 1-1000 pieces for planning group 0##. The routing should be copied hierarchically from the pump with material number T-F2## and group counter 1. Before copying, set the indicator for Set target context after copying on the Misc. tab page.

2.

Check the routing with BOM and the component assignments for the pump with material number T-F##, and then save and exit the Engineering Workbench.

Task 3: Copy an operation for a similar pump. 1.

2003/Q2

Copy operation 50 with its corresponding components from the routing for material R-F1## to operation 45 in the T-F## routing. Continued on next page

© 2004 SAP AG. All rights reserved.

91

Unit 5: Engineering Workbench

PLM111

Use the additional selection criteria in the Engineering Workbench, and enter the material numbers for pumps T-F## and R-F1##. Use the browser to copy the operation. 2.

In the operation overview, check the copied operation. Select Save to exit editing in the EWB.

Task 4: Open the Engineering Workbench with the working area P_ALLES for material T-F## and T-F1##.

92

1.

Use the browser to display an overview of the production resources/tools for pump T-F1## in plant 1000.

2.

Search for the production resource/tool PP-FHMS in your routings by using the browser. Navigate to the details screen.

3.

You have assigned the hollow shaft to operation 40 in your routing for material T-F##. Reassign this assignment to operation 45 by using the browser.

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Structure of the Engineering Workbench

Solution 4: Using the EWB Browser Task 1: Complete an assignment using the Engineering Workbench. 1.

In the routing for the T-F2## pump with group counter 1, assign the flywheel to operation 20, and the hollow shaft to operation 40. Save the assignments, but do not exit the Engineering Workbench. a) b)

Choose the P_ALLES working area and the T-F2## material, and then click Load Task Lists and BOMs . On the Headers overview, select the row with the group counter 1. Select Task Lists → Component Assignments. There are several possibilities.

c) d) e)

Confirm the EWB: Process Using dialog box with the specified key date. Enter an operation number for each item. Save the component assignments, but do not exit the EWB.

Task 2: Create a routing with BOM by copying multi-level. 1.

Now create a routing with BOM for the T-F## material with a lot size of 1-1000 pieces for planning group 0##. The routing should be copied hierarchically from the pump with material number T-F2## and group counter 1. Before copying, set the indicator for Set target context after copying on the Misc. tab page. a) b) c)

Return to the Headers Overview, and select Copy Object . In the Target Data dialog box, change the material number to T-F##, and delete the task list group number. Set the Copy hierarchically indicator. button to set the indicators for the relevant Choose the Copy Range copy objects in the EWB: Options dialog box. In the EWB: Options dialog box, set the Set target context after copying indicator on the Misc. tab page.

d)

Now copy the routing and change the lot-size area. Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

93

Unit 5: Engineering Workbench

2.

PLM111

Check the routing with BOM and the component assignments for the pump with material number T-F##, and then save and exit the Engineering Workbench. a)

Double-click the light bulb in the O column to view the operations.

Task 3: Copy an operation for a similar pump. 1.

Copy operation 50 with its corresponding components from the routing for material R-F1## to operation 45 in the T-F## routing. Use the additional selection criteria in the Engineering Workbench, and enter the material numbers for pumps T-F## and R-F1##. Use the browser to copy the operation. a) b) c) d) e) f) g)

2.

Click the Additional Selection Criteria button in the EWB. Click Multiple Selection , and enter R-F1## and T-F## as material numbers. Click Load Task Lists and BOMs . Select Display Tree to enable the browser. Confirm the dialog box EWB: Process Using with the specified key date. Click the arrow in front of material number R-F1## and navigate through the routing and the standard sequence to the operations. Use the same method to navigate to the operation overview for material T-F##. In operation 50 for material R-F1##, right-click and choose Multi-level Copy from the context menu. Select the standard sequence of the routing as the target object. Right-click Paste and enter operation 45.

In the operation overview, check the copied operation. Select Save to exit editing in the EWB. a)

Right-click the standard sequence in the routing for material T-F## and select Operations to go to the operations overview.

Continued on next page

94

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Structure of the Engineering Workbench

Task 4: Open the Engineering Workbench with the working area P_ALLES for material T-F## and T-F1##. 1.

Use the browser to display an overview of the production resources/tools for pump T-F1## in plant 1000. a)

Select Additional Selection Criteria in the EWB. Click Multiple Selection , and enter T-F1## and T-F## as material numbers.

b) c) 2.

Search for the production resource/tool PP-FHMS in your routings by using the browser. Navigate to the details screen. a) b) c)

3.

Select Find . In the Find dialog box, select the object type PRT and enter PP-FHMS. Double-click the search result to select the production resource/tool in the upper browser screen. Double-click again in the upper screen to get to the production resource/tools details.

You have assigned the hollow shaft to operation 40 in your routing for material T-F##. Reassign this assignment to operation 45 by using the browser. a) b)

2003/Q2

Click Load Task Lists and BOMs . Right-click the line in the browser for the routing for material T-F1## and navigate to Production Resources and Tools.

Drill down in the browser structure and reassign the hollow shaft to operation 45 by clicking and dragging. Close the browser and exit the EWB without saving.

© 2004 SAP AG. All rights reserved.

95

Unit 5: Engineering Workbench

PLM111

Lesson Summary You should now be able to: • Use the Engineering Workbench for extensive routing maintenance • Use the EWB browser functions

96

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Using Different Working Areas and Selection Options

Lesson: Using Different Working Areas and Selection Options Lesson Overview This unit explains the Engineering Workbench lock logic and other selection options.

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

Select and use working areas

Business Example You would like to find the optimum maintenance environment for permanent changes. You would like to make changes simultaneously. You would also like to create new master data and link them in a hierarchy.

Worklist and Focus Using the selection criteria that you enter, you immediately determine which focus objects are contained in your worklist. The focus objects form the core of your worklist. Focus objects meet the selection criteria you create. An environment object is an object whose object type is contained in the working environment and that is assigned to a focus object. Environment objects are automatically selected by the system, and represent the environment of the focus object that you are interested in.

2003/Q2

© 2004 SAP AG. All rights reserved.

97

Unit 5: Engineering Workbench

PLM111

Figure 36: Objects in the Worklist

An example for loading operations in the worklist by selecting according to the work center: • •

If the focus is set on the operation, then only those operations that use this work center are read into the worklist. If the focus is set on the routing header, then the operations that are contained in the routings are also read into the worklist.

In the figure Focus on Header, the focus is on the Header object type. In addition to the focus routing header, the object types sequence, operation, PRT, trigger point, inspection characteristic, BOM header, item and subitem should all be contained in the working environment. A work center has been entered as selection criteria.

98

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Using Different Working Areas and Selection Options

Figure 37: Example: Focus on Routing Header

The figure depicts the following process: 1.

2. 3. 4.

All routing headers are copied with their sequences and operations to the worklist, provided that one of the operations contains this work center. Additionally, the objects that are connected to the operation and whose object type is included in the working environment are also copied to the worklist. All BOM headers that are assigned to these routing headers are copied to the worklist. All objects that are on a lower level to these BOM headers are copied to the worklist. All component assignments that are between the operations of the routing header and the items of the assigned BOM headers are copied to the worklist.

In the figure Focus on Operation, the focus is on the Operation object type. In addition to the focus operation, the following object types should all be contained in the working environment: Routing header, sequence, PRT, trigger point, inspection characteristic, BOM header, item and sub-item. A work center has been entered as selection criteria.

2003/Q2

© 2004 SAP AG. All rights reserved.

99

Unit 5: Engineering Workbench

PLM111

Figure 38: Example: Focus on Operation

The figure depicts the following process: 1. 2. 3. 4.

All objects that are at a higher or lower level than the focus objects covered by these work center operations are copied to the worklist. All items that are assigned to these operations, including the component assignments, are copied to the worklist. All objects that are on a higher or lower level than these items are copied to the worklist. The assignments between routing headers and BOM headers, determined in steps 1 and 3, are copied to the worklist.

The figure Routing: Different Focus shows the expected results based on the focus.

100

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Using Different Working Areas and Selection Options

Figure 39: Routing: Different Focus

Prerequisite for the respective result is that the working area always contains the same object types. Use the Extras menu entry to view working area and selection criteria details.

Effectivities and Selection Criteria You can filter the objects on display in the overview screen with the help of the effectivity window. The example in this figure is of a working area with four operations. The operations have been partially changed. If you choose the selection period in the effectivity window, all operations that are effective in the selection period are displayed. If you restrict the effectivity window, the operations that lie completely outside of the effectivity window are not displayed. If you choose the key date in the effectivity window, only those operations that are effective on the key date are displayed.

2003/Q2

© 2004 SAP AG. All rights reserved.

101

Unit 5: Engineering Workbench

PLM111

Figure 40: Routing Effectivities

You can use the selection range to restrict the time period for the data. Only data that lies entirely or partially in the effectivity period is copied to the worklist.

Figure 41: Selection Criteria

The system automatically offers the tab page in which the object of the focus has been placed. When entering the selection criteria you can switch the tab page.

102

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Using Different Working Areas and Selection Options

You can use the arrow key on the tab page to enter in fields additional selection criteria that is not contained as selection criteria on the tab pages on the screen. In addition, you can also use this procedure when you want to select according to several individual values, value intervals or generically. The buttons for additional selection criteria refer to various database tables. On the header tab page the material-routing assignments are in the upper block, and the routing headers are in the lower block.

Material-Routing Assignment A material can be assigned to different routings. The routings in a group are differentiated by the group counter. Routings can be clearly identified by their group and group counter values. Groups contain routings that have similar production processes. In this way multiple routings can be in one group, for example, for different lot sizes or production alternatives. One routing can be used to produce different materials, for example, mirrored parts, such as left-hand car doors and right-hand car doors. You can even assign these different materials to different plants.

Figure 42: Material-Routing Assignment

2003/Q2

© 2004 SAP AG. All rights reserved.

103

Unit 5: Engineering Workbench

PLM111

104

2003/Q2

© 2004 SAP AG. All rights reserved.

PLM111

Lesson: Using Different Working Areas and Selection Options

Exercise 5: Selection Options Exercise Objectives After completing this exercise, you will be able to: • Assign materials to a routing • Use EWB locking logic

Business Example You are responsible for maintaining master data for BOMs and routings in your company; to do this you use the common maintenance interface in the Engineering Workbench.

Task 1: Create an overview of the routings that you created. 1.

Select the P_ALLES working area. Use the function Created by in the additional selection criteria.

2.

Check whether the groups displayed belong to your products.

3.

Why did you select this working area?

4.

How many routings did you create?

Task 2: When creating the routing for your pump T-F##, it occurs to you that your routing can also be used for the production of pump P-100. 1.

Make a material-routing assignment.

2.

In the BOM for pump P-100, change the quantity of the component hex bolt M10 to the number of your group.

3.

A dialog box may appear that prevents you from making this change. Determine who is also changing the BOM item and ask them to unlock it. Hint: To lift the lock you need to exit the transaction.

2003/Q2

4.

Could you change another BOM item in the same BOM without the lock being lifted?

5.

Save the changes and exit the EWB.

© 2004 SAP AG. All rights reserved.

105

Unit 5: Engineering Workbench

PLM111

Solution 5: Selection Options Task 1: Create an overview of the routings that you created. 1.

Select the P_ALLES working area. Use the function Created by in the additional selection criteria. a)

Select the P_ALLES working area. Select Initialize selection criteria. On the Header tab page, click the lower button. In Explorer, select Created by. Complete the field with your user name and select Save.

2.

Check whether the groups displayed belong to your products. a)

3.

Why did you select this working area? a)

4.

Select Task Lists → Material-Task list assignments. The working area P_ALLES allows you to enter additional selection criteria for the header.

How many routings did you create? a)

Two routings.

Task 2: When creating the routing for your pump T-F##, it occurs to you that your routing can also be used for the production of pump P-100. 1.

Make a material-routing assignment. a)

2.

Copy the group from T-F## by clicking Set/Reset Data in Context in the context menu and enter the material number P-100.

In the BOM for pump P-100, change the quantity of the component hex bolt M10 to the number of your group. a)

Select material P-100 on the Material-routing assignments gen. tab page, and choose Bills of Material → Items. Select the line with the hex bolt and change the quantity to ##.

Continued on next page

106

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Using Different Working Areas and Selection Options

3.

A dialog box may appear that prevents you from making this change. Determine who is also changing the BOM item and ask them to unlock it. Hint: To lift the lock you need to exit the transaction. a)

4.

Could you change another BOM item in the same BOM without the lock being lifted? a)

5.

Yes

Save the changes and exit the EWB. a)

2003/Q2

Carry out the steps listed above.

Carry out the steps listed above.

© 2004 SAP AG. All rights reserved.

107

Unit 5: Engineering Workbench

PLM111

Lesson Summary You should now be able to: • Select and use working areas

108

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Unit Summary

Unit Summary You should now be able to: • Use the Engineering Workbench for extensive routing maintenance • Use the EWB browser functions • Select and use working areas

2003/Q2

© 2004 SAP AG. All rights reserved.

109

Unit Summary

110

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Test Your Knowledge

Test Your Knowledge

2003/Q2

1.

Name the four focus objects.

2.

What does the working area consist of?

© 2004 SAP AG. All rights reserved.

111

Test Your Knowledge

PLM111

Answers 1.

Name the four focus objects. Answer: Routing headers, operations, BOMs and items.

2.

What does the working area consist of? Answer: The working area contains the focus and the working environment. The working environment can contain all remaining object types.

112

© 2004 SAP AG. All rights reserved.

2003/Q2

Unit 6 Processing Routings Unit Overview Unit Contents • • • • • • •

Alternative routings Alternative and parallel sequences Suboperations Reference operation sets Scrap Where-used lists and mass changes Changes with history

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

Use alternative routings Use alternative and parallel sequences Describe the functions of suboperations Retrieve additional fields in operations Use reference operation sets Describe the types of scrap Use where-used lists and mass changes Make changes with history

Unit Contents Lesson: Sequences in Routings .................................................. 115 Lesson: Suboperations and User-Defined Fields............................... 120 Lesson: Reference Operation Set, Work Center Operation Set .............. 125 Exercise 6: Reference Operation Set, Work Center Operation Set...... 127 Lesson: Scrap and Its Effects ..................................................... 135

2003/Q2

© 2004 SAP AG. All rights reserved.

113

Unit 6: Processing Routings

PLM111

Lesson: Reporting and Mass Changes .......................................... 138 Lesson: Task List Changes with the Change Master .......................... 141 Exercise 7: Task List Changes with the Change Master .................. 145

114

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Sequences in Routings

Lesson: Sequences in Routings Lesson Overview This lesson explains how to deal with aIternative and parallel routing sequences.

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

Use alternative routings Use alternative and parallel sequences

Business Example Within the project team you are responsible for routing management. Your company makes products with various order lots that require specific production cycles. You therefore maintain additional routing alternatives for these products.

Production Version Different production lot sizes may require alternative production methods for reasons of efficiency. In the example illustrated below, a product is manufactured using two sets of technologies and methods. This necessitates different routings and different BOMs.

2003/Q2

© 2004 SAP AG. All rights reserved.

115

Unit 6: Processing Routings

PLM111

Figure 43: Production Version

Version 0001 produces brackets for large order lots on an NC punching machine. The bracket is punched whole from a metal sheet. Because it takes longer to set up a NC punching machine than the actual time it takes for punching, version 0002 is used to produce small quantities of brackets with another manufacturing process. This process requires strips of metal. The appropriate alternative is selected using the production version in the material master. The production version determines the manufacturing process according to the routing and BOM specified. You can store multiple production versions for different lot size intervals in the material master. The group counter values differentiate the individual routings.

116

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Sequences in Routings

Sequences in Routings

Figure 44: Sequences in Routings

Alternative sequences are linked to the standard sequence. Branch operations in the standard sequence are ignored in the procedure. Parallel sequences are special types of overlapping operations.

Figure 45: Parallel Sequences

Parallel sequences can be used in various industries, for example: •

2003/Q2

In mechanical engineering for assembly lines with individual component manufacturing: A parallel sequence allows for several individual components from the BOM to be prepared as smaller units for final assembly.

© 2004 SAP AG. All rights reserved.

117

Unit 6: Processing Routings

PLM111

In the chemical industry for analytical processes that occur parallel to the production process. An alignment key defines the start of the individual parallel sequences and consequently the position of the sequence buffers.

118

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Sequences in Routings

Lesson Summary You should now be able to: • Use alternative routings • Use alternative and parallel sequences

2003/Q2

© 2004 SAP AG. All rights reserved.

119

Unit 6: Processing Routings

PLM111

Lesson: Suboperations and User-Defined Fields Lesson Overview This lesson covers suboperations and user-defined fields for operations.

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

Describe the functions of suboperations Retrieve additional fields in operations

Business Example You are responsible for routing management in the project team. You would like to calculate more detailed costs of operations and therefore use suboperations. You use user-defined fields for transferring data in the operation from other systems.

Suboperations and User-Defined Fields Suboperations provide responsible production areas detailed resource planning below the scheduled main operations. They are not scheduled. For capacity requirements in suboperations, it is possible to set up reference dates for the main operation, as for PRTs. Suboperations are hierarchically structured under an operation and are used to carry out more detailed capacity planning or costing. For example, suboperations are used in a company at manufacturing centers. In the figure, operation 20 is responsible for compliance with the production schedule. Suboperations 20/10 to 20/40 are used for exact capacity planning and costing.

120

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Suboperations and User-Defined Fields

Figure 46: Suboperations

The control key has an important influence on this process. It is important that you make sure when using suboperations that costs and capacity requirements are not calculated twice. Scheduling always takes place only at operation level.

Figure 47: Scheduling Suboperations

2003/Q2

© 2004 SAP AG. All rights reserved.

121

Unit 6: Processing Routings

PLM111

The dates of the suboperations are determined using the start or finish reference for an operation when you specify an offset value. The reference dates for the start and finish of a suboperation are: • • • • • •

Start date for setup Start date for processing Start date for teardown Finish date for execution Start date for wait time Finish date for wait time

If an operation is divided into suboperations, the standard values for the suboperations can be cumulated under the main operation. If the suboperations run in parallel, this kind of cumulation is not possible because the cumulated values would be too high. Example: If you set a start reference for a suboperation to start processing with a time offset of 5- (5 minus) hours, processing in the suboperation will start 5 hours before it does in the main operation. User-defined field keys can be used to add more input fields for user data in the operation screen.

Figure 48: User-Defined Fields in Operations

122

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Suboperations and User-Defined Fields

This field key makes the following fields available: • • • • • •

Two text fields (20 characters) Two text fields (10 characters) Two date fields Two fields for quantity and unit of measure Two fields for value and/or currency Check boxes

In Customizing, users create a field key name and then enter a field name for each additional field. The quantity fields can be used as formula parameters in formulas for calculating execution time and capacity requirements. These fields can also be used in product costing.

2003/Q2

© 2004 SAP AG. All rights reserved.

123

Unit 6: Processing Routings

PLM111

Lesson Summary You should now be able to: • Describe the functions of suboperations • Retrieve additional fields in operations

124

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Reference Operation Set, Work Center Operation Set

Lesson: Reference Operation Set, Work Center Operation Set Lesson Overview This lesson covers work center operation sets.

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

Use reference operation sets

Business Example You are responsible for routing management in the project team. You would like to find out how to use standard procedures using reference operation sets.

Reference Operation Sets

Figure 49: Reference Operation Set

A reference operation set is used to describe a frequently-used sequence of operations. It can be used either as a reference or as a template when you create a routing. A reference operation set does not allow parallel or alternative sequences. You can assign a material to a reference operation set.

2003/Q2

© 2004 SAP AG. All rights reserved.

125

Unit 6: Processing Routings

PLM111

You can use a template to create a reference operation set either with a routing or reference operation set. If you copy from a routing, only the basic sequence is copied. If you copy from a reference operation set, there is no reference. Reference operation sets can only be referenced in a routing by using the operation overview.

Figure 50: Work Center Operation Set

A work center operation set is a cumulated reference operation set and can not be exploded any further in a routing. You need a higher-level work center for standard value cumulation. You must trigger the standard value cumulation manually. Detailed operation descriptions along with the executing work centers are not included. You can manually overwrite the cumulated standard values. You cannot assign objects to a work center operation set. They are copied from the reference operation set.

126

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Reference Operation Set, Work Center Operation Set

Exercise 6: Reference Operation Set, Work Center Operation Set Exercise Objectives After completing this exercise, you will be able to: • Create a reference operation set and include it in a routing. • Apply parallel sequences. • Assign production resources/tools to an operation.

Business Example You are responsible for defining manufacturing data used to support the production of the new pump. These definitions include: • • •

Introducing a gauge as a production resource/tool to be used during final assembly inspection Creating frequently used operations as reference operation sets Creating the routing for the new pump

Task 1: You can define standard processes in the form of reference operation sets for the final inspection of the pump. 1.

Use the EWB to create a reference operation set for the final inspection. The reference operation set should have the status Released (general) and be used for production. Planner group 0## is responsible. Enter Inspection group ## as the description. Hint: Do not forget to enter your planner group and the description. It helps you find your reference operation set using the external number assignment.

2.

The reference operation set consists of one operation, which is done in work center T-P. You copy the control key and the standard text key with the operation description from the work center. The standard value for labor is 10 minutes.

3.

Save the reference operation set, and exit the EWB.

Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

127

Unit 6: Processing Routings

PLM111

Task 2: Create an alternative routing for the new pump T-F##. Use the data sheet for material T-F## for the routing header data and the operations. The pump can be produced in a total of 8 steps: 5 in the standard sequence and 3 in a parallel sequence. 1.

First of all, create the standard sequence for pump T-F##. Create operation 50 for the final inspection using the reference operation set from exercise 1-1. This operation cannot be changed in the routing. Data sheet for the alternative routing (standard sequence) Header data Material

T-F##

Usage:

Production

Status:

Creation phase

Planner group:

0##

Lot size

1 to 100 pieces

Operation data for the standard sequence with processing time in minutes

Op.

Work center

Short text

Setup

Mach.

Labor

10

T-M

(Default text from the work center)

10

0

0

20

T-E

Pre-assembled pump

30

0

10

30

T-P

(Default text from the work center)

0

0

5

40

Center##

(Default text from the work center)

30

10

0

50

T_P

(Default text from the work center)

0

0

10

Continued on next page

128

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Reference Operation Set, Work Center Operation Set

2.

After you have saved your routing you notice that to check the inspection instruction in operation 50 you need an inspection gauge. Assign the inspection gauge as production resource/tool PP_FHMM in plant 1000 to this operation and be aware of the mass changes to the operation data. Check the assignment on the operations overview.

3.

Using the data sheet, create the parallel sequence for group counter 2 to pump T-F## in order to process a sheet of metal. The parallel sequence has to be checked with the standard sequence for operation 30. Data sheet for the alternative routing (standard sequence) Operation data for the parallel sequence with processing time in minutes

Op.

4.

2003/Q2

Setup

Mach.

Labor

10

Work Short text center T-V Cut raw material

10

10

0

15

T-V

Drill holes

0

0

5

20

T-L

(Default text from the work center)

15

5

5

Now add to the BOM the variable-size item T-MS05, with measurements 80 x 50mm, for processing the sheet metal, and assign this to the parallel sequence for operation 10.

© 2004 SAP AG. All rights reserved.

129

Unit 6: Processing Routings

PLM111

Solution 6: Reference Operation Set, Work Center Operation Set Task 1: You can define standard processes in the form of reference operation sets for the final inspection of the pump. 1.

Use the EWB to create a reference operation set for the final inspection. The reference operation set should have the status Released (general) and be used for production. Planner group 0## is responsible. Enter Inspection group ## as the description. Hint: Do not forget to enter your planner group and the description. It helps you find your reference operation set using the external number assignment. a)

Create a reference operation set. Logistics → Production → Engineering Workbench Click Initialize selection criteria, Load Task Lists and BOMs, and then Create.

b)

Create a reference operation set header Enter the task list type S and on the Headers general tab page, the description Inspection group ##, your planner group and the status Released (general).

2.

The reference operation set consists of one operation, which is done in work center T-P. You copy the control key and the standard text key with the operation description from the work center. The standard value for labor is 10 minutes. a)

Create operation To insert the operation, double-click column O.

3.

Save the reference operation set, and exit the EWB. a)

Carry out the steps listed above.

Continued on next page

130

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Reference Operation Set, Work Center Operation Set

Task 2: Create an alternative routing for the new pump T-F##. Use the data sheet for material T-F## for the routing header data and the operations. The pump can be produced in a total of 8 steps: 5 in the standard sequence and 3 in a parallel sequence. 1.

First of all, create the standard sequence for pump T-F##. Create operation 50 for the final inspection using the reference operation set from exercise 1-1. This operation cannot be changed in the routing. Data sheet for the alternative routing (standard sequence) Header data Material

T-F##

Usage:

Production

Status:

Creation phase

Planner group:

0##

Lot size

1 to 100 pieces

Operation data for the standard sequence with processing time in minutes

Op.

Work center

Short text

Setup

Mach.

Labor

10

T-M

(Default text from the work center)

10

0

0

20

T-E

Pre-assembled pump

30

0

10

Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

131

Unit 6: Processing Routings

PLM111

Operation data for the standard sequence with processing time in minutes

30

T-P

(Default text from the work center)

0

0

5

40

Center##

(Default text from the work center)

30

10

0

50

T_P

(Default text from the work center)

0

0

10

a)

Create alternative routing Logistics → Production → Master Data → Engineering Workbench Enter the material number T-F##, and click Load Task Lists and BOMs, and then Create. On the Headers general tab page, enter the lot size 1 to 100.

b)

Create operations. Double-click column O Enter the operations 10 to 40, and, for operation 50, insert the reference operation set from exercise 1-1. Operation → Create Reference to Reference Op. Set

2.

After you have saved your routing you notice that to check the inspection instruction in operation 50 you need an inspection gauge. Assign the inspection gauge as production resource/tool PP_FHMM in plant 1000 to this operation and be aware of the mass changes to the operation data. Check the assignment on the operations overview. a)

Assign the production resources/tool to the reference operation set. Click Deselect all objects and then Set/Reset Data in Context. In the row with task list type S, double-click the column Pr. to enter the inspection gauge PP-FHMM. Go to the Material tab page. Task Lists → Operations.

3.

Using the data sheet, create the parallel sequence for group counter 2 to pump T-F## in order to process a sheet of metal. The parallel sequence has to be checked with the standard sequence for operation 30. Continued on next page

132

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Reference Operation Set, Work Center Operation Set

Data sheet for the alternative routing (standard sequence) Operation data for the parallel sequence with processing time in minutes

Op.

Setup

Mach.

Labor

10

Work Short text center T-V Cut raw material

10

10

0

15

T-V

Drill holes

0

0

5

20

T-L

(Default text from the work center)

15

5

5

a)

Create the parallel sequence Task Lists → Sequences, set the routing group with the group counter 2 in the context and click Create for the selected one. Choose Parallel sequence and enter operation 20 as the return operation. You are already familiar with the procedure for entering an operation text and standard values.

4.

Now add to the BOM the variable-size item T-MS05, with measurements 80 x 50mm, for processing the sheet metal, and assign this to the parallel sequence for operation 10. a)

Bills of Material → Items and then click Create. Bills of Material → Component assignment

2003/Q2

© 2004 SAP AG. All rights reserved.

133

Unit 6: Processing Routings

PLM111

Lesson Summary You should now be able to: • Use reference operation sets

134

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Scrap and Its Effects

Lesson: Scrap and Its Effects Lesson Overview This lesson deals with the maintenance options for scrap.

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

Describe the types of scrap

Business Example In the project team, you are responsible for routing management. For a part of the product, the company needs to be able to schedule scrap. You are responsible for the correct maintenance.

Scrap

Figure 51: Scrap categories and their effects

Scrap is used for material requirements planning and product costing. Component scrap only refers to an individual component of an assembly.

2003/Q2

© 2004 SAP AG. All rights reserved.

135

Unit 6: Processing Routings

PLM111

During BOM explosion, the system increases only the component quantity by the calculated scrap quantity, for example, a component is broken regularly during the manufacturing process. Assembly scrap is only used when the material is an assembly. Reasons for the assembly scrap include inadequate quality or bad working conditions, such as heat, cold, or dampness. In MRP, the system increases the material requirement for all components contained in the assembly by the scrap quantity calculated for the components. Operation scrap in the BOM identifies the quantity of a component to be processed in an operation. The specification replaces the estimated assembly scrap for the high-quality materials and allows a more precise MRP. The net indicator controls that the operation scrap for components is calculated without taking into account the assembly scrap (net input quantity). You have to set this indicator even if no operation scrap has been maintained and you do not want the assembly scrap to be taken into account. Operation scrap in the operation results in a fall in quantity in the next operation and is taken into consideration during scheduling and costing. The scrap percentages maintained in the operations are written into the material master when the scheduling is updated.

136

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Scrap and Its Effects

Lesson Summary You should now be able to: • Describe the types of scrap

2003/Q2

© 2004 SAP AG. All rights reserved.

137

Unit 6: Processing Routings

PLM111

Lesson: Reporting and Mass Changes Lesson Overview This lesson deals with mass changes and reporting.

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

Use where-used lists and mass changes

Business Example In the project team, you are responsible for the where-used lists and the mass changes in routing management.

Reporting and Mass Changes

Figure 52: Where-used lists

Where-used lists can be generated for work centers, capacities, production resources/tools, and reference operation sets.

138

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Reporting and Mass Changes

Figure 53: Routings / reference operation sets - reports

You can use the Replace function to make mass changes to the following: • • •

2003/Q2

Work centers PRTs Reference operation sets

© 2004 SAP AG. All rights reserved.

139

Unit 6: Processing Routings

PLM111

Lesson Summary You should now be able to: • Use where-used lists and mass changes

140

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Task List Changes with the Change Master

Lesson: Task List Changes with the Change Master Lesson Overview This lesson covers changes to routings with documentation.

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

Make changes with history

Business Example You are responsible for routing management in the project team. Your company must document the changes in its BOMs and routings. You are responsible for ensuring changes are documented with history.

Change with a Change Master Record

Figure 54: Why Make Changes with Engineering Change Management?

Engineering change management is a central logistics function that can be used to change various types of master data and document the changes. By using a valid-from date for the change master record, the changes become valid on a predefined date. This aids long-term planning.

2003/Q2

© 2004 SAP AG. All rights reserved.

141

Unit 6: Processing Routings

PLM111

You can use engineering change management to store certain SAP objects (for example, BOMs and routings) more than once. This means that you can store the objects in all relevant change statuses. The changes take effect automatically at the predefined time in all areas of the logistics process chain, for example, sales order, material requirements planning and shop floor control. You can use engineering change management to group together changes to different SAP objects that are affected by one change. You can change all the objects at the same time or you can define different change dates for individual objects. You can use engineering change management to help fulfill your legal obligations regarding documentation of changes.

Figure 55: Engineering Change Management

You can make object changes (for example: BOM and routing changes) in the SAP system either with or without history. However, you should be aware that change documents are created by the system even for changes without history.

142

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Task List Changes with the Change Master

Changes Without History These are changes that must be documented because they take place during production, for example. 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 prior to the change is not saved. You can only find out indirectly about the status of the object before the change by using change documents. Changes with History Both the status before and after the change is saved. The system creates change documents. For some objects, these change documents differ from those created for changes without history. Engineering change management in the SAP system enables you to fully document changes. Some of these changes may be needed for product liability purposes, for example.

Figure 56: Object Type Indicators – Change Master Record

The following indicators control processing with the change number for the individual object types: Active = Object type for the change number is active: You must set this indicator if you want to process objects with the change number for the object type concerned. Object = An object management record is required for each object: If you set this indicator, then you can only make a change to an object of the object type concerned if you create an object management record for the object first.

2003/Q2

© 2004 SAP AG. All rights reserved.

143

Unit 6: Processing Routings

PLM111

MgtRec = Object management record is generated: If you set this indicator, the system generates an object management record automatically when you process with the change number (create or change) an object of the object type concerned. If you set this indicator, all objects of the object type concerned with the change number can be changed. Gen new = Generate on first creation: If you set this indicator, an object management record is only created automatically when you create an object of the object type concerned. In this case, if you want to process an existing object with the change number, create an object management record manually first. GenDial = Generate on first creation: With automatic object generation, the system opens a dialog screen where you can enter object-specific documentation. (Exception: Sales order BOM). Lock = Object type locked for changes: You can lock and unlock the object type as required.

144

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Task List Changes with the Change Master

Exercise 7: Task List Changes with the Change Master Exercise Objectives After completing this exercise, you will be able to: • Use where-used lists and mass changes • Make documented changes and evaluate them

Business Example You are required to make changes to routings with a history of the changes and therefore use the change master record to make these changes.

Task 1: Solve the following problem: 1.

The inspection requirements for pump T-F## for the routing with group counter 2 have changed, and you need to adjust the inspection gauge accordingly. You ensure that this inspection gauge is not being used in other routings and execute a where-used list for the production resources/tools (PRT) PP-FHMM.

Task 2: The where-used list shows that this PRT is being used in other products. You decide to use a suitable PRT in your routing. This routing change must be documented. 1.

Create change master AE-GR## and the description Change master ## for the change with history. The change should be active for routings for the first working day in the next month. Cross-Application Components → Engineering Change Management → Change Number → Create

2.

Using the change master record AE-GR##, replace the production resource/tool PP-FHMM with the miscellaneous production resource/tool PP-FHMS and enter a setup time of 5 minutes for this operation. Hint: Change the PRT in the reference operation set by adding the miscellaneous type of PRT and deleting PP-FHMM. Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

145

Unit 6: Processing Routings

3.

PLM111

Save the changes and exit the EWB.

Task 3: Solve the following problem: 1.

Check the changes by using an explosion for the current date as the key date and the current date + 2 months as the key date.

Task 4: Solve the following problem: 1.

Work center T-P## has been revised. This enables a 10 percent reduction in labor time for all operations that are being done at this work center. Use the EWB to make a mass change for all the operations in the routings that you are responsible for and with the change number AE-GR##.

Task 5: Solve the following problem: 1.

You only want to see the changes with change number AE-GR## in the operations with the work center T-P##. Describe the procedure. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

146

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Task List Changes with the Change Master

Solution 7: Task List Changes with the Change Master Task 1: Solve the following problem: 1.

The inspection requirements for pump T-F## for the routing with group counter 2 have changed, and you need to adjust the inspection gauge accordingly. You ensure that this inspection gauge is not being used in other routings and execute a where-used list for the production resources/tools (PRT) PP-FHMM. a)

Logistics → Production → Master Data → Production Resources/Tools → Reporting → Task Lists for PRT Enter the PRT number and types N to S.

Task 2: The where-used list shows that this PRT is being used in other products. You decide to use a suitable PRT in your routing. This routing change must be documented. 1.

Create change master AE-GR## and the description Change master ## for the change with history. The change should be active for routings for the first working day in the next month. Cross-Application Components → Engineering Change Management → Change Number → Create a)

Enter the change number AE-GR## and press Enter. Then enter the description, date and status 01. Confirm your entries and set the indicator in the Active column for the task list.

Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

147

Unit 6: Processing Routings

2.

PLM111

Using the change master record AE-GR##, replace the production resource/tool PP-FHMM with the miscellaneous production resource/tool PP-FHMS and enter a setup time of 5 minutes for this operation. Hint: Change the PRT in the reference operation set by adding the miscellaneous type of PRT and deleting PP-FHMM. a)

EWB, then click Initialize selection criteria. On the Header tab page, enter material T-F## and the group counter 2. Load Task Lists and BOMs → Task Lists + click Set/Reset Data in Context. Task Lists → Production Resources/Tools. Select the PRT and click Change. In the dialog box EWB: Process Using, enter the change number. Delete the PRT and go to the Miscellaneous tab page to enter the new PRT. Enter the setup time for the reference operation set.

3.

Save the changes and exit the EWB. a)

Carry out the steps listed above.

Task 3: Solve the following problem: 1.

Check the changes by using an explosion for the current date as the key date and the current date + 2 months as the key date. a)

Call the EWB again, and look at the key-date explosion for the date in the Process Using field.

Continued on next page

148

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Task List Changes with the Change Master

Task 4: Solve the following problem: 1.

Work center T-P## has been revised. This enables a 10 percent reduction in labor time for all operations that are being done at this work center. Use the EWB to make a mass change for all the operations in the routings that you are responsible for and with the change number AE-GR##. a)

So that you get only the operations that use this work center, change to working area where the focus is on the operation. Click Select Working Area. – V_ALLES Select the work center T-P## in plant 1000 on the Operation tab page and your group 0## for plant 1000 on the Header tab page. Click Load Task Lists and BOMs. Go to the Processing time tab page, select the operations and click Change. Hint: Because outing T-F## has already been changed with the change master, you have to enter the change number AE-GR## in the EWB: Process Using dialog box. To initiate the mass change, select the all the operations again and the labor time column. Choose Extras → Mass Change. In the EWB: Operations Mass Change dialog box, click Enter Formulas. Confirm the information and enter the formula 0.9*x in the Enter Formulas dialog box.

Task 5: Solve the following problem: 1.

You only want to see the changes with change number AE-GR## in the operations with the work center T-P##. Describe the procedure. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

149

Unit 6: Processing Routings

PLM111

___________________________________________________________ a)

Call the EWB with the working area focused on the operation. Enter the change number on the Change Number tab page. Set the indicator for the Operat. object. Click Load Task Lists and BOMs.

150

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Task List Changes with the Change Master

Lesson Summary You should now be able to: • Make changes with history

2003/Q2

© 2004 SAP AG. All rights reserved.

151

Unit Summary

PLM111

Unit Summary You should now be able to: • Use alternative routings • Use alternative and parallel sequences • Describe the functions of suboperations • Retrieve additional fields in operations • Use reference operation sets • Describe the types of scrap • Use where-used lists and mass changes • Make changes with history

152

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Test Your Knowledge

Test Your Knowledge 1.

What are the ways of changing an operation of a referenced reference operation set in a routing? Choose the correct answer(s).

2.

2003/Q2

□ □ □

A B C

□

D

It cannot be done. You must unlock the operation of the reference operation set. You must unlock the entire reference operation set. This copies the reference operation set, and you can change the operation. You must change the operation in the reference operation set if you want the change to apply to all reference operation set usages.

Why should you make routing changes using a change master?

© 2004 SAP AG. All rights reserved.

153

Test Your Knowledge

PLM111

Answers 1.

What are the ways of changing an operation of a referenced reference operation set in a routing? Answer: C, D

2.

Why should you make routing changes using a change master? Answer: To document changes. The status before and after the change is saved. This also allows you to produce spare parts according to an older status.

154

© 2004 SAP AG. All rights reserved.

2003/Q2

Unit 7 Scheduling Unit Overview Unit Contents • • •

Time components and their origins Scheduling a routing Updating the scheduling result

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

Assess the importance of lead time scheduling and updating in-house production time in the material master Maintaining the scheduling-relevant data in the work center Explain the connection between formulas and standard values Update the in-house production time of the routing in the material master

Unit Contents Lesson: Understanding Lead Time Scheduling and Material Master Updates .............................................................................. 156 Lesson: Work Center Integration ................................................. 160 Lesson: Formula Connections .................................................... 165 Lesson: Time Components, Reduction Possibilities ........................... 169 Exercise 8: Scheduling ........................................................ 173

2003/Q2

© 2004 SAP AG. All rights reserved.

155

Unit 7: Scheduling

PLM111

Lesson: Understanding Lead Time Scheduling and Material Master Updates Lesson Overview This lesson describes the importance of lead time scheduling and updating in-house production time in the material master.

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

Assess the importance of lead time scheduling and updating in-house production time in the material master

Business Example As a member of the project team, you are responsible for the precise time scheduling of your products. To ensure this can happen, you need to first fulfill the following prerequisites: • • •

Maintain working times Maintain in-house production time in the material master Prepare reduction measures

Understanding Lead Time Scheduling and Material Master Updates Material requirements planning explodes a material's BOM, generates planned orders or purchase requisitions for the components to be procured, and calculates basic order dates. Basic order dates (planned dates) are calculated using the in-house production time or the planned delivery time in the material master. The in-house production time for a material can be calculated using lead time scheduling of a routing without an order, and then copied to the material master.

156

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Understanding Lead Time Scheduling and Material Master Updates

Figure 57: Scheduling and Calculation of Basic Order Dates

Production planning has two types of scheduling that are implemented in different ways: Material requirements planning and lead time scheduling.

Figure 58: Scheduling in Production Planning

2003/Q2

© 2004 SAP AG. All rights reserved.

157

Unit 7: Scheduling

PLM111

To ensure smooth materials requirement planning, it is absolutely necessary to schedule a routing, and to update the material master with the scheduling results. If materials requirement planning (MRP) is carried out without scheduling (as shown in the top half of the graphic), capacity requirements are not determined for planned orders. You can also use lead time scheduling to determine capacity requirements for planned orders in MRP. Production orders are always scheduled using lead time scheduling for the operations. A production order always contains both sets of dates (basic dates and baseline dates). Baseline dates are relevant for production.

Figure 59: Scheduling and Purpose of In-House Production Time

You maintain the in-house production time in the material master. To calculate basic dates correctly in requirements planning, it is very important that the in-house production time in the material master agrees with the results of lead time scheduling in the routing.

158

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Understanding Lead Time Scheduling and Material Master Updates

Lesson Summary You should now be able to: • Assess the importance of lead time scheduling and updating in-house production time in the material master

2003/Q2

© 2004 SAP AG. All rights reserved.

159

Unit 7: Scheduling

PLM111

Lesson: Work Center Integration Lesson Overview This lessen gives an overview of the scheduling-relevant fields in the work center.

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

Maintaining the scheduling-relevant data in the work center

Business Example As a member of the project team, you are responsible for the precise time scheduling of your products. Therefore the operating time must be stored in the work center.

Work Center Integration The standard value key and formula keys in the work center form the basis for scheduling, capacity planning and costing.

Figure 60: Work center integration

160

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Integration

You can maintain the available capacity for machinery or staff, for example. If one capacity is assigned to several work centers, it is considered a pooled capacity. You should maintain the available capacity of a pooled capacity separately in the work center capacity menu. The effectivity of an available capacity can be interrupted by an interval of available capacity with a limited effectivity period. You can maintain intervals of available capacity using shift sequences.

Figure 61: Capacity Categories for a Work Center in SAP R/3

You must assign formulas to calculate capacity loads on the screen for available capacity.

2003/Q2

© 2004 SAP AG. All rights reserved.

161

Unit 7: Scheduling

PLM111

Figure 62: Available Capacity Maintenance Using Central Shift Sequences

Shift sequences and shift definitions can be used for the detailed maintenance of the available capacity for each capacity category only if you use intervals. Shift sequences and shift definitions can be created and selected for special areas in Customizing with the help of the grouping key. You define the work start, work finish and break times for all work centers in a shift definition. In shift sequences, you maintain the sequence of individual shift definitions for all shift sequences.

162

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Work Center Integration

Figure 63: Scheduling data at a work center

The move time can be maintained separately in an operation. You can maintain a minimum move time and a normal move time in the Interoperation times section of the Operation detail screen. If reduction measures are necessary, the system uses the minimum move time for scheduling. Note: The system uses the move time matrix to determine move times only if you have not entered any move times in the Interoperation times section of the operation detail screen . As a rule, however, the transport time should be determined by means of the location groups from the sequential work centers and the move time matrix in Customizing. You can group work centers that are close together in a location group. You maintain location groups in Customizing In the scheduling data screen for the work center, you assign the work center to a location group. In the move time matrix, you can maintain the planned move times within a location group or between two location groups and several plants. You can maintain the queue time in the work center and in the routing operation. However, the system uses the queue time from the work center for scheduling only if you have not maintained a queue time in the operation. If reduction measures are necessary, the value is reduced from the normal queue time to the minimum queue time.

2003/Q2

© 2004 SAP AG. All rights reserved.

163

Unit 7: Scheduling

PLM111

Lesson Summary You should now be able to: • Maintaining the scheduling-relevant data in the work center

164

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Formula Connections

Lesson: Formula Connections Lesson Overview This lesson introduces the lead time scheduling formulas.

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

Explain the connection between formulas and standard values

Business Example As a member of the project team, you are responsible for the precise time scheduling of your products. You have to ensure that the formulas can be supplied with values.

Formula Connections The standard values defined for the routing and the formulas defined in the work center are used in lead time scheduling to calculate the execution time for the individual time segments (setup, processing, teardown). If you use splitting, you must also take into account the formula parameters in the formula for the number of splittings.

2003/Q2

© 2004 SAP AG. All rights reserved.

165

Unit 7: Scheduling

PLM111

Figure 64: Execution Time

You assign formula definitions for calculating execution time and capacity requirements in the work center. The formulas themselves are saved in Customizing as formula definitions. You must first maintain the parameters used in the formula definitions as formula parameters in Customizing. You use standard value keys to determine entry fields for the standard values of an operation. The standard values entered in these fields are used to calculate execution time and capacity requirements.

166

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Formula Connections

Figure 65: Formulas and Standard Values

2003/Q2

© 2004 SAP AG. All rights reserved.

167

Unit 7: Scheduling

PLM111

Lesson Summary You should now be able to: • Explain the connection between formulas and standard values

168

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Time Components, Reduction Possibilities

Lesson: Time Components, Reduction Possibilities Lesson Overview This lesson places particular importance on updating the material master with the result of lead-time scheduling.

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

Update the in-house production time of the routing in the material master

Business Example As a member of the project team, you are responsible for the precise time scheduling of your products. To ensure this can happen, you need to first fulfill the following prerequisites: • •

Maintain in-house production time in the material master Prepare reduction measures

Time Components and Reduction Possibilities The two float times serve different purposes: Float before production Is used to shift the date and plan capacities. Float after production Is used to deal with malfunctions.

2003/Q2

© 2004 SAP AG. All rights reserved.

169

Unit 7: Scheduling

PLM111

Figure 66: Scheduling and Time Components in an Order

The order float can be predefined in Customizing and the material master (scheduling margin key). The duration of an operation consists of a maximum of five time components: • • • • •

Queue time Setup time Processing time Teardown time Process-related wait time

The duration of the move time lies between two operations but is assigned to the preceding operation. The material requirement is scheduled from the earliest start date (you can change this in Customizing). The capacity requirement can be displayed on the earliest or latest start date.

170

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Time Components, Reduction Possibilities

Figure 67: Time Components and their Origins

You maintain time elements for lead time scheduling in various places within the PP application. It is important to make the correct settings and use the system properly for successful scheduling. The interoperation time in the material master is calculated from: • • • •

Order float (float before and after production) Operation float (queue time) Wait time Move time

The system can carry out reduction measures in lead time scheduling for orders.

2003/Q2

© 2004 SAP AG. All rights reserved.

171

Unit 7: Scheduling

PLM111

Figure 68: Reduction Measures

You can set the time elements that can be reduced as well as the reduction strategy in Customizing (for each order category and planner group). You can also specify reduction for the floats before and after production in the order or in Customizing for each plant, order type and planner group.

172

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Time Components, Reduction Possibilities

Exercise 8: Scheduling Exercise Objectives After completing this exercise, you will be able to: • Schedule routings and update the in-house production time in the material master.

Business Example As a member of the project team you are responsible for feasible and exact scheduling of the company’s products. The following prerequisites need to be fulfilled: • • •

Lead time scheduling of a routing Preparation of reduction measures Maintain in-house production time in the material master

Task 1: Solve the following problem: 1.

Use the operation graphic to check the correct production cycle in group counter 2 for pump T-F##. Hint: The operation graphic and scheduling in routing can only be done with transaction CA03. Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display

Task 2: Schedule the new pump T-F## with group counter 2. 1.

Schedule the pump T-F## with a forwards scheduling direction from the current date, and for a quantity of 50 pieces. Use the operation segments overview variant to view the schedule data.

2.

Why is no processing time calculated in the standard sequence for operation 20 if a labor time of 10 minutes has been correctly defined?

3.

Display the Gantt chart for your scheduling. Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

173

Unit 7: Scheduling

PLM111

4.

Display the scheduling log and check the types of messages you have received, if any.

5.

Check the scheduling results. How many interoperation times are scheduled?

6.

Mark the material master for T-F## to be updated with your scheduling results.

Task 3: Update the in-house production time in the material master, for production scheduler 0##, for T-F##. 1.

Update the production lead-times based on the marking activity you did in exercise 2-6.

2.

Check the results of your update in the material master for T-F##. Are the values that have been updated dependent or independent of lot size? Hint: As an alternative, you can do the mass scheduling with an automatic update in the material master instead of doing lead time scheduling for each individual routing. Logistics → Production → Master Data → Routings → Extras → Material Master → Schedule Material Master

174

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Time Components, Reduction Possibilities

Solution 8: Scheduling Task 1: Solve the following problem: 1.

Use the operation graphic to check the correct production cycle in group counter 2 for pump T-F##. Hint: The operation graphic and scheduling in routing can only be done with transaction CA03. Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display a)

Enter the material number T-F##, and the group counter 2. Click Sequence Overview and Operation graphic.

Task 2: Schedule the new pump T-F## with group counter 2. 1.

Schedule the pump T-F## with a forwards scheduling direction from the current date, and for a quantity of 50 pieces. Use the operation segments overview variant to view the schedule data. a)

Extras → Scheduling → Schedule. Enter the lot size 50 in the scheduling dialog box. Choose the overview variant 0......1.

2.

Why is no processing time calculated in the standard sequence for operation 20 if a labor time of 10 minutes has been correctly defined? a)

3.

Display the Gantt chart for your scheduling. a)

4.

The labor time has been defined, but the machine time is needed to complete the work center formula. Choose Gantt Chart or Extras → Scheduling → Gantt Chart.

Display the scheduling log and check the types of messages you have received, if any. a)

Choose Scheduling Log or Extras → Scheduling → Display Log. Continued on next page

2003/Q2

© 2004 SAP AG. All rights reserved.

175

Unit 7: Scheduling

5.

PLM111

Check the scheduling results. How many interoperation times are scheduled? a)

6.

Select Scheduling Results or Extras → Scheduling → Scheduling Results.

Mark the material master for T-F## to be updated with your scheduling results. a)

In the Scheduling Results dialog box select Update Material Master to mark the scheduling result for the update.

Task 3: Update the in-house production time in the material master, for production scheduler 0##, for T-F##. 1.

Update the production lead-times based on the marking activity you did in exercise 2-6. a)

Logistics → Production → Master Data → Routings → Extras → Material Master → Update Material Master Make sure you select only your T-F## for the update. When the update has been completed you get the message: The material has been changed.

2.

Check the results of your update in the material master for T-F##. Are the values that have been updated dependent or independent of lot size? Hint: As an alternative, you can do the mass scheduling with an automatic update in the material master instead of doing lead time scheduling for each individual routing. Logistics → Production → Master Data → Routings → Extras → Material Master → Schedule Material Master a)

Logistics → Production → Master Data → Material Master → Material → Display → Display Current Choose the Work Scheduling screen to display the estimated in-house production times.

176

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Lesson: Time Components, Reduction Possibilities

Lesson Summary You should now be able to: • Update the in-house production time of the routing in the material master

2003/Q2

© 2004 SAP AG. All rights reserved.

177

Unit Summary

PLM111

Unit Summary You should now be able to: • Assess the importance of lead time scheduling and updating in-house production time in the material master • Maintaining the scheduling-relevant data in the work center • Explain the connection between formulas and standard values • Update the in-house production time of the routing in the material master

178

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Test Your Knowledge

Test Your Knowledge 1.

What is the lot size dependent in-house production time in the material master used for? Choose the correct answer(s).

□ □ □ □ 2.

2003/Q2

A B C D

Determine precise operation dates in planning Determine precise basic order dates in planning Determine the base quantity Mandatory requirement for creating an order

What steps are required to write the lot size dependent in-house production time to the material master?

© 2004 SAP AG. All rights reserved.

179

Test Your Knowledge

PLM111

Answers 1.

What is the lot size dependent in-house production time in the material master used for? Answer: B

2.

What steps are required to write the lot size dependent in-house production time to the material master? Answer: • • • • •

180

View a routing Schedule a routing View a scheduling result Flag for material master update Update material master

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Course Summary

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

Maintain routings and work centers Assign material components to operations Determine lead time and enter it in the material master

Related Information Recommended follow-up activities • • • •

2003/Q2

Go through the exercises again. Use IDES data or your own data. Read the online documentation. Read the IMG documentation. Read the release notes.

© 2004 SAP AG. All rights reserved.

181

Course Summary

182

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

Appendix 1 Menu Paths

Frequently-used menu paths Routing Maintenance Menu Paths

2003/Q2

Process a routing using the Engineering Workbench

Logistics → Production → Master Data → Engineering Workbench

Replace a work center

Logistics → Production → Master Data → Routings → Extras → Mass Changes → Replace Work Center

Replace a reference operation set

Logistics → Production → Master Data → Routings → Extras → Mass Changes → Reference Operation Sets

Replace a production resource/tool

Logistics → Production → Master Data → Routings → Extras → Mass Changes → Replace PRT

Display routings and schedule

Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display

Update material master

Logistics → Production → Master Data → Routings → Extras → Material Master → Update Material Master

Schedule and update selected material masters

Logistics → Production → Master Data → Routings → Extras → Material Master → Schedule Material Master

Create Standard Texts

Logistics → Production → Master Data → Routings → Extras → Standard Text

© 2004 SAP AG. All rights reserved.

183

Appendix 1: Menu Paths

PLM111

Routing Maintenance Menu Paths Where-used list for work center

Logistics → Production → Master Data → Routings → Reporting → Where-Used List → Work Center

Where-used list for reference operation set

Logistics → Production → Master Data → Routings → Reporting → Where-Used List → Reference Operation Set

Where-used list for production resources/tools

Logistics → Production → Master Data → Routings → Reporting → Where-Used List → Prod.Resources/Tools

Menu Paths for Material Master Maintenance Create

Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately

Change

Logistics → Production → Master Data → Material Master → Material → Create → Immediately

Display

Logistics → Production → Master Data → Material Master → Material → Display → Display Current

Menu Paths for Work Center Maintenance

184

Create

Logistics → Production → Master Data → Work Centers → Work Center → Create

Change

Logistics → Production → Master Data → Work Centers → Work Center → Change

Display

Logistics → Production → Master Data → Work Centers → Work Center → Display

Replace a work center

Logistics → Production → Master Data → Work Centers → Work Center → Replace

Create capacity

Logistics → Production → Master Data → Work Centers → Capacity → Create

Change capacity

Logistics → Production → Master Data → Work Centers → Capacity → Change

Display capacity

Logistics → Production → Master Data → Work Centers → Capacity → Display

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Appendix 1: Menu Paths

Menu Paths for Work Center Maintenance Create hierarchy

Logistics → Production → Master Data → Work Centers → Hierarchy → Create

Change hierarchy

Logistics → Production → Master Data → Work Centers → Hierarchy → Change

Display hierarchy

Logistics → Production → Master Data → Work Centers → Hierarchy → Display

Menu Paths for Production Resources/Tools Create production Logistics → Production → Master Data → Production resource/tool with material Resources and Tools → Production Resources/Tools → Material → Create (General) Change production Logistics → Production → Master Data → Production resource/tool with material Resources and Tools → Production Resources/Tools → Material → Create → Immediately

2003/Q2

Create other production resource/tool

Logistics → Production → Master Data → Production Resources and Tools → Production Resources/Tools → PRT Master (Misc.) → Create

Change other production resource/tool

Logistics → Production → Master Data → Production Resources and Tools → Production Resources/Tools → PRT Master (Misc.) → Change

© 2004 SAP AG. All rights reserved.

185

Appendix 1: Menu Paths

186

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

Appendix 2 Extra Slides

Figure 69: Example: Focus on Header

The focus is on the object type BOM header. In addition to the focus on the BOM header, the object types item and subitem, header with sequence, operation, PRT, trigger point and inspection characteristic should all be contained in the working environment. A component has been entered as selection criteria.

2003/Q2

© 2004 SAP AG. All rights reserved.

187

Appendix 2: Extra Slides

PLM111

1: All BOM headers, with their items and subitems, are copied to the worklist that contains these components. 2: All task list headers belonging to the BOM headers of these components are copied to the worklist. 3: The objects that are connected to the header and whose object type is included in the working environment are also copied to the worklist. 4: All component assignments among items in the BOM headers and the operations for the corresponding routings are copied to the worklist.

Figure 70: Example: Focus on Item

The focus is on the object type item. With the focus on the item, the following object types should also be included in the working environment: BOM header and subitem, routing header with sequence, operation, PRT, trigger point and inspection characteristic. A component has been entered as selection criteria. 1: Only the items that correspond to these components are copied to the worklist with their BOM headers and subitems. 2: All operations to which this component has been assigned are copied to the worklist.

188

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Appendix 2: Extra Slides

3: The objects that are connected to this operation and whose object type is contained in the working environment are also copied to the worklist, for example header, sequence and so on. 4: As a further restriction, the material/routing assignment is taken into account.

Figure 71: BOM Group

The SAP system saves for the BOM group all alternatives for a multiple BOM, or all BOMs that have been entered for a variant BOM. To maintain a BOM group, you must have set the indicator for group processing in Customizing for the work center. You maintain the BOM group displayed in the context block on the BOM header overview screen. Caution: If changes are made to BOM items in Item Group Maintenance Overview that are valid for all alternative BOMs or variants, you need to activate group maintenance.

2003/Q2

© 2004 SAP AG. All rights reserved.

189

Appendix 2: Extra Slides

PLM111

Figure 72: Digital Mockup Viewing

You can use the digital mockup function to visualize products and components as 3D models in the Engineering Workbench from anywhere in the company. The SAP system gets the required product information from a CAD system. You use the CAD interface to copy BOMs and CAD documents from your CAD system to your SAP system. The system converts the CAD documents to a 3D format (such as *.JT) that can be visualized. This file is checked in to the SAP system as an original document management application file and is managed using a document info record.

190

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Appendix 2: Extra Slides

Figure 73: Effectivity Types and Effectivity Parameters

When making changes with change numbers, you can also use the Engineering Workbench to make changes using parameter effectivities. The SAP system also enables you to link the effectivity of change numbers to other effectivity types. By default, the effectivity types time interval (DATE) and serial number interval (SERNR) are defined with the effectivity parameters time interval (DATE), serial number interval (SERNR) and material number (MATNR). You then have to assign value to these effectivity parameters when maintaining change numbers and also when using objects that have been processed using such change numbers. By using the time interval (DATE) effectivity type, you can control object changes that are, for example, only relevant on a seasonal basis or for a specific time period. By using the serial number interval (SERNR), you can control change statuses based on the serial number of a finished product. The parameter combination material (single value) and serial number (open interval) uses the effectivity type serial number interval. As it would be practically impossible to represent all possible variants of effectivity types within the scale of standard software, Customizing for engineering change management allows you to determine additional effectivity types with user-defined parameters.

2003/Q2

© 2004 SAP AG. All rights reserved.

191

Appendix 2: Extra Slides

PLM111

Figure 74: Planned Scrap – Example

Assembly scrap calculation from operation scrap entered on the routing. Assembly scrap equals 11.11%. Formula: Total scrap quantity (10) divided by total yield (90) Operation no.

Scrap

Start quantity

Scrap quantity

Operation yield

10

5%

100

5

95

20

5%

95

5

90

Based on the component scrap and operation scrap values defined in the BOM or routing, the system calculates the following planned component quantities:

192

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Appendix 2: Extra Slides

Material

Consumption

Assembly

Components BOM

Op.

Req.

Scrap %

Scrap %

Scrap %

Net

Quantity

Operation Billet

10

12%

2%

0%

N

115

Screws

30

12%

7%

0%

Y

107

Gasket

30

12%

3%

0%

Y

103

Execution time: Operation

Production Quantity

Time Target

Required Time (h)

10

112

10 hour

11.2

20

106

10 hour

10.6

30

101

5 hour

20.2

Figure 75: External Processing

External processing allows production operations performed outside of your facilities to be defined in the same manner as internal operations. The vendor is treated as an extension of your production facility.

2003/Q2

© 2004 SAP AG. All rights reserved.

193

Appendix 2: Extra Slides

PLM111

If you want to use external processing, you must select a control key that allows this. When you create an operation, you need to enter purchasing data in the operation detail screen. The following details are required entries: • • • • •

Purchasing organization Sort string Material group Planned delivery time Cost element

Figure 76: Backflushing: Settings

To use backflushing effectively, the material components from the BOM that are required in the operation should be assigned to the operations in the routing. By assigning components to an operation, you specify that these materials are first required at this point in time. When the operation is confirmed, the values and the quantities of the components are posted. Backflush determination is a multi-step process: • •

194

First the system looks at the component assignment data. If the Backflush indicator has been set, then backflush occurs when the confirmation is received. If not set, the system checks the material master. If the Backflush indicator has not been set, then no backflush occurs.

© 2004 SAP AG. All rights reserved.

2003/Q2

PLM111

Appendix 2: Extra Slides

If you set Always backflush, then backflush occurs. If you set Work center decides, then the work center, depending on whether the indicator has been set there, determines whether a backflush occurs. Operations that are not milestones should have a control key, in which confirmations are possible, although not required or forbidden.

2003/Q2

© 2004 SAP AG. All rights reserved.

195

Appendix 2: Extra Slides

196

PLM111

© 2004 SAP AG. All rights reserved.

2003/Q2

Appendix 3 Data Used in the Exercises

Type of Data Material master

Data in the Training System

Template

T-F00 to T-F20

T-F1##

TP-F00 to TP-F20

T-F1##

T-B00 to T-B20

400-431

T-T00 to T-T20

Routing

T-F200 to T-F220 R-F100 to R-F120

Work center

T-M##, T-V##, T-L##, T-E##, T-F## T-P##, T-P, T-V, Center##

Production resources/tools – document

2003/Q2

PP-FHMM, PP-FHMS T-D06 (DRW 000 00)

© 2004 SAP AG. All rights reserved.

197

Appendix 3: Data Used in the Exercises

PLM111

198

2003/Q2

© 2004 SAP AG. All rights reserved.

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

2003/Q2

© 2004 SAP AG. All rights reserved.

199