SAP PP MRP Manual for Newbies
Short Description
In this manual, MRP procedure steps are covered with exemplary data in SAP....
Description
User Training Document
NTF (INDIA) PVT. LTD.
SAP USER TRAINING DOCUMENT MRP By Kanti Kumar
1
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Experts agree that you get the most from your ERP software when users become accepting, comfortable, and proficient performing the new business processes the software supports. In other words, much of the success of a multimillion dollar ERP implementation depends on the people using the system for day-to-day work.
Our Aims and Ideals To train you on higher level in SAP ERP, that is our aim.
2
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
MRP Process in SAP System We run MRP for generating Vendor Schedules. This document will show process in SAP for Production plan to material receive from vendors through SAP system. First we focus on Production Plan. We receive Schedules from our Customers as: Schedule from Maruti for July 2nd For Night OE & Spare Schedule Both Plant (Manesar & Gurgaon)
3
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Other Customers and spare parts Schedule will be provided by Mr. Bharat.
4
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
On the basis of these delivery schedules Production Plan will be prepared. RTM and Paint Shop for Unit 1 and Unit 2 Production plan prepared by Mr. Uday. Mr. Uday will fill Production plan in these sheets. Mr. R.K. Gupta should help for preparation Production Plan for Unit 2 for RTM products. Production Plan (RTM and Paint Shop) for Unit 1
Production Plan (RTM and Paint Shop) for Unit 2
5
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
TCM Production Plan for Unit 1 and Unit 2 will be prepared by Mr. Satybir. Mr. Satybir will fill Production plan in these sheets. Mr. R.K. Gupta should help for preparation Production Plan for Unit 2 for RTM products. Production Plan (TCM) for Unit 1
Production Plan (TCM) for Unit 2
6
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
PIM Production Plan for Unit 1 will be prepared by Mr. Satybir. Mr. Satybir will fill Production plan in this sheet: Production Plan (PIM) for Unit 1
We are running our PIM machines only on Electricity so daily planning is not possible for PIM department. We are taking monthly planning from PIM.
Preparation to run MRP in SAP System: These are the main points for run smooth MRP. 1. Inventory: Now our Physical and SAP system Inventory is matching. 2. Open Purchase Requisition: When we will run MRP old PR will be deleted automatically. 3. Open Purchase Orders: We will close old Purchase Orders. 4. Open Schedule Lines in Scheduling Agreements. 5. Open Production Orders: We will close all old unused Production Orders (TECO). 6. Open Planned Orders: We will close old Planned Orders. 7. Reorganizing Independent Requirements 8. Independent Requirements reorganization 9. Recorg. Independent Requirements 10. Delete Planned Independent Requirements 11. Create (Planned Independent Requirements ) Production Plan in SAP System Finally Run MRP with
MD02
7
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
2. Open Purchase Requisition: When we will run MRP open Purchase Requisition will be closed automatically. Manually created Open Purchase Requisition will be closed with this. We will close Open Purchase requisition on both NTF Unit 1 and Unit 2.
Tcode: ZPR_DELETE
3. Open Purchase Orders: We should close open Purchase Orders. For getting list of open Purchase Orders these TCODE will be used. ME2M, ME2L, ME2N
1) 2) 3) 4)
Make delivered quantity equal to order qty. Block PO line items Delete line items if there is no open GR’s or invoices. Open Purchase orders will be close for both NTF Unit 1 and NTF Unit 2. 8
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
4. Open Schedule Lines in Scheduling Agreements. We will get the list of open Scheduling Lines in Schedule Agreements. Open Schedule Lines should be close for both NTF Unit 1 and NTF Unit 2 plants. TCODE: ZOPENSHL
This is the list of open Schedule Lines. We should close these Schedule Lines in SAP System. These Schedule Lines should not appear. These Schedule Lines are the vendor Schedules and we should receive these materials in last month but not received and schedule lines are pending. Now close schedule line in Scheduling Agreement. 9
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
TCODE: ME38
Enter Scheduling Agreement Number and press enter key.
10
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Delete Qty.
5. Open Production Orders: We should close open production orders. For getting open production orders
TCODE: COOIS
11
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
12
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Take the list of Open production orders. Open production order for (TECO) closing. TCODE: CO02
13
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
14
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Save the production Order. If Quantity of open Production Orders is high then we should close in mass. TCODE: COHV
15
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
16
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
17
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Other condition for getting open Production Orders
18
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Select layout as Standard Layout and press Select All tab right side on order screen.
Select Mass Processing Tab.
19
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Select Technical Complete and press copy button then press
6. Open Planned Orders 20
NTF Technik India Pvt. Ltd.
execute button.
User Training Document
NTF (INDIA) PVT. LTD.
For getting list of open Planned order and delete open planned order this tcode required.
TCODE: MD16
21
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Press Select All as per below given screen.
22
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Press Delete All. All Open Planned Orders from NTF Unit 1 and NTF Unit 2 should delete from the SAP System.
23
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
7. Reorganizing Independent Requirements (Run for NTF Uint1 and NTF Unit2) TCODE: MD74
Press to
for run this utility. It will show this type of results.
24
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
8. Independent Requirements reorganization (Run for NTF Uint1 and NTF Unit2) TCODE: MD75
Press to
for run this utility. It will show this type of results
25
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
9. Recorg. Independent Requirements (Run for NTF Uint1 and NTF Unit2) TCODE: MD76
Press to
for run this utility. It will show this type of results
26
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
10.Delete Planned Independent Requirements
We enters production plan on daily basis for run MRP. For enter next month production plan we should delete old Planned Independent requirement (production plan).
TCODE: MD62
We should delete all of these entries.
27
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Data Selection in the fields:
The select of data in these fields is very important. (1) Product Group: We have created two main product groups.
TCODE: MC84 NTFUNIT1: For enter production planning for NTF Unit 1
28
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
NTFUNIT2: For enter production planning for NTF Unit 2
For display all Product Group we will use this Tcode. TCODE: MC85
29
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
We want to see the Members of Product Group then user this:
TCODE: MC85 For NTFUNIT1 (Manesar Plant) product Group these are the members:
For NTFUNIT2 (Neemrana Plant) product Group these are the members:
30
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
For Add or change the Materials in product Group Members we will use this tcode.
TCODE: MC86
31
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
32
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Add the Material and plant in the list and before save it press “Distribute
proportns”
Now Press save button for save material in product group member list. Other Fields Data Selection for delete and enter production Plan:
Please check all marked fields according to document. Enter planning horizon date according you production plan. 33
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Create Planned Independent Requirements (Enter Production Plan): TCODE: MD61
Enter Daily Production Plan and save.
34
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
The below screen is the production planning cycle
35
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Sales Order
Create Planned Independent Requirements MD61
LTP
Check In Stock Requirement List MD04
Planning Run Transfer into Operative Planning
MD4C
MD02
Capacity Availability Check
Multi Items
Single Item Multi Level
Finite Scheduling Online
Background
Convert Planned Order into Production Order
1. Check Material Availability 2. Check Capacity Availability
CO02
> Click Material Button > Click Capacity Button
Release Order
Order Confirmation & Scrap (FINAL)
CO02
Click on Green FLAG button and SAVE
CO15
MB31 Movement type 101,Sto. Loc. SPF1
Goods Receipt to FG Store (SPF1) 36
CO40 or MD04
> Enter Pld Order no >OK > Save > Prod order no generated
Excess Goods Issue for production Orders
NTF Technik India Pvt. Ltd.
Partial Confirmation
Rework Rework Confirmation MB1A
(Store Department)
> movement type - 261 > Production Oder No.
User Training Document
NTF (INDIA) PVT. LTD.
PLANNING RUN (MRP RUN) Def: The execution of materials planning for all materials or assemblies that have the nessary entries in the planning file. Planning File: A file that contains a list of all materials for which a change relevant to requirements planning has occurred and that are automatically flagged for planning. If such a change has taken place, the entry in the planning file is performed automatically. We need not do anything as everything is done automatically but to check planning file the TCODE is MZD21. For this type of ne change planning, only materials that change relecant to MRP in the period are planned in the planning run. There are several types of planning run. 1. Total planning on-line TCODE = MD01 2. Single item-multi level TCODE = MD02 3. Single item – single level TCODE = MD03 4. Total planning back-ground TCODE = MD04 Here we run MRP back-ground every week once but we may require running MRP foreground sometimes for single item.
TCODE: MD02
37
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Enter the material to which planning is required. MRP Control Parameters. Processing Key: Enter NETCH Create purchase req: Select 2 for purchase requisition in the opening period. Delivery Schedules: Select 3 for schedule lines. Create MRP list : Enter 1 for MRP List. Planning Mode : Re-explode BOM and routing. Scheduling : Lead time Scheduling and capacity planning. Process Control Parameters Tick Also plan Unchanged components. Tick display results before they are saved. Tick display material list. After entering the above details press enter. You get notification that “please check input parameters”. Again press enter.MRP run will takes place and you can observe the following screen.
Press
Save button.
38
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
First Select “Proceed without stopping” radio button and then Press Continue Tab
39
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Press Material
Tab on the screen for getting Material List.
40
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
We get the information of all the dependent materials. Planned orders are created for items that are not available on date. For in-house production dependent requirements we get planned orders and for external procurements items we get either planned order or purchase requisitions depending upon the time availability of converting planned orders to purchase requisitions in opening period. The MRP controller will check the planning result and make changes if required in dates and quantities. The system carries out the following processes in the planning run: 1) The system checks the planning file. During this process, the system checks whether a material is to be planned due to a change relevant to MRP, and how to proceed if there are already existing procurement proposals. 2) The system calculates net requirements for every material. For this calculation, the system checks whether the requirements are covered by the warehouse stock and dispatched receipts from Purchasing or Production. If the requirements cannot be covered, the system creates a procurement proposal. 3) The system calculates procurement quantities. When doing this, the system takes into account the selected lot-sizing procedure and, if necessary, scrap and rounding values. 4) The system carries out the scheduling in order to calculate the start and finish dates for the procurement proposals. 5) The system determines the type of procurement proposal. Dependent upon the defined setting, planned orders, purchase requisitions or delivery schedules are created by the system for a material. 6) For every procurement proposal of an assembly, the system explodes the BOM and determines the dependent requirements. 7) During the planning run, the system recognizes critical situations that have to be assessed manually in the planning result by the work scheduler. The system creates exception messages and, if necessary, checks rescheduling.
41
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Stock Requirement List: In this list we can see all planned orders, Ind. Requirement and Vendor Schedule lines. TCODE: MD04
42
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Master Data: Material Master We should enter correct Master data in SAP system. This is to inform you all who are creating new Material Master Data, Routing or BOM (with similar components and work centers), are not adapting standard procedures. After creating Material in Material Master, problem occurs at the time of production order creation or material consumption or report generation. The easiest and simplest way to create a Material Master data is to copy from the old material or routing or BOM and edit wherever necessary so that chances of committing errors can be reduced. So I am requesting you all who are responsible for master data creation, let us not invent the wheel again. Use Simplest way to create a Material in Material Master Data is to copy from the old materials.
Enter old Material number for Copy the material.
Some views are very important for run MRP. Please check these views: MRP1 MRP2 MRP3 MRP4 Accounting Costing
43
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
MRP 1 View:
MRP 2 View
44
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
MRP 3 View
MRP 4 View
45
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Account 1 View
S: Standard price for Finished and semi-finished goods. V: Moving price for Raw Materials
Enter or Check Profit Center
46
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Purchasing View
Please check Unit of measure/EANs in Purchasing View -> Additional Data Tab.
47
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
WORK SCHEDULING View
Issue Storage Location: In the case of a material produced in-house, this is the key of the storage location that is copied to the planned order or production order. Production Scheduler: Scheduler responsible for a material in production activity control. The production scheduler determines how capacity requirements are calculated for a material during a scheduling run. Production Scheduling Profile: Profile that you can use to Specify that certain business transactions are carried out in parallel in a production order / process order (you can, for example, create and release an order at the same time, or release an order and print the shop papers) Trigger an automatic goods receipt Specify an overall profile for capacity leveling
Serial No Profile: The data grouped under a four-digit identification code that defines the conditions and operations for assigning serial numbers for serialized materials. 48
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
The serial number profile must be entered in the master record of the material for which the items are assigned serial numbers. Batch entry: Defines when batches have to be determined. We have the following options The batches can be determined when the goods issue is posted. The batches must be entered in the order before it is released. The batches must be entered in the order before the goods issue is posted, but not necessarily before the order is released The batches are determined automatically when the order is released
Batch management: Specifies whether the material is managed in batches. In house production time in days(Lot size dependant): Set up and tear down time: Specifies the number of workdays needed to set up and tear down the various work centers where the material is processed. This value is the total of the setup and teardown times. The setup and teardown time is independent of the order quantity. Processing time: Specifies the time needed to process the material in the operations at the different work centers. The processing time depends on the order quantity. Base quantity: Quantity to which the in house production time and the processing time of the material relate. We can also upload this data from routings. When we maintain values for lot size dependent in-house production time in days we have to carefully enter the values because it should be always equal or greater than the timings from routings, otherwise the system will reduce the operation timings even though our intension is not that.
49
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Maintain MRP 2 View storage location in MMSC. TCODE: MMSC
50
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
PRODUCTION VERSION MAINTENANCE IN MATERIAL MASTER Production version is the combination of BOM’s and Routings and should be maintained in the material master under the following conditions. Mainly this PV is used in the finished goods material master. Consider GYPSY HARD TOP for example. There are two versions of hard top we make for GYPSY, they are Milky white and Olive Green with the same item code for ex.93610m83F00-26U. When we create production order without creating PV, system will select Alternate BOM 1 and Routing Group 1 for this item. Since we have two different BOM’s for this item (two colors) we should have an option to choose one that we manufacture and here it is not possible. Also while planning material procurement it is difficult to plan for Alternate BOM 2 materials. So PV is must in such case. When there is a difference of operation times for two different items of same item code, it is difficult to select which process we adopt to manufacture the item or if there more than one process available to make an item ( such as alternate routing) it is only possible with PV. Here is a demo to create the PV in material master for item 93610M83F00-26U Create different BOM’s for 93610M83F00-26U, such as alt BOM1 and alt BOM2. Create different routings for 93610M83F00-26U (if required). Now in the material master MRP 4 View click on PV
Here we need to create version as 0001, 0002 and so on along with validity
Here I am creating version 0003 as test 1 and click on details and the following screen appears. Fill the details such as lot size, valid from and to date, task list type and alternate BOM as under 51
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Click on check and you should get the following screen.
If both task list and BOM exists check status will become green as under
52
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Continue and create as many versions as needed and save. One another configuration setting required in material master is in MRP 4 tab page
Select 2 0r 3 in BOM selection method. This is how we have to maintain PV for different items with same item code. As there is a need to maintain PV I am providing this document to all the users who create the material master.
53
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
BOM: Bill of Material Creation and updating is the responsibility of Engineering Department. For getting change document (changes in the BOM) follow this process:
Go To Environment Tab and press Change Document:
54
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Press Document Overview All change documents:
Click on the doc. No. for getting details.
55
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Where-Used List: Materials This Tcode shows the materials used in BOM component.
TCODE: CS15
List of all components where this material is using.
56
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Multi-Level BOM Report: Menu Transaction Code
ZPP_BOM
57
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
58
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
For Searching Raw Material used in BOM Enter Raw Material in (For material List BOM Component)
59
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Creation of Routing T-code: CA01
Pic. Shows the initial screen of creation of routings and the T-code is CA01. We have to enter the material code for which we are going to create routing in the Material field. We have to enter plant (7777). Go to Header of the routing.
60
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Enter the task list description. Enter the task list usage as production. Enter the status as 4 which indicate this routing or task list is released (general). Enter the lot size if anything is applicable. Come back the initial screen. Position the cursor on the operations field and enter.
61
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
The operations screen appears.
The operational increment is 10 by default. Enter the work center assigned to the operation, in work center field. Enter the control key in the field CO. The control key determines which business transactions should be executed for the object that belongs to the task list or order. The business transactions are whether the operations are included in scheduling. Costing automatic goods receipt, mile stone conformation etc. Enter the description of each operation. Enter the base quantity, by default system takes 1. Enter the Standard values (for ex. setup, labor etc).The standard values are planned values for executing an operation. Standard values are used in costing, scheduling, and capacity planning to calculate costs, execution times, and capacity requirements. The setup operation is not depended upon the quantity but all other operations are depended upon the operation quantity. Ex. Set up time =45min (die change).There we don’t enter any machine or labor time.
62
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
The Next operation if it is done in machine work center we have to enter machine time and if labor works then enters labor time. In the Assembly work center where there is only labor involves enter labor time. These timings are called standard values and used in calculation of capacities, scheduling and costing functions. Component allocations:
We have to assign materials to operations. The procedure is.. 1) Click on component allocations and select materials and click on new assignment. In the operation details all the operations are displayed. Select and assign materials to operations and save. The routing is saved with group and group counter. If we have similar routings for several materials we can copy the routings .The procedure is described below.
63
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Enter the material to which the routing is to be created and click on copy from and selct routing from the pop up screen. We get the below screen.
Fill up the material name from which we want to copy the routings and click on copy and we get the operations copied. We can edit for changes.
64
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Creation of Work Centers An organizational unit that defines where and when an operation must be performed The work center has an available capacity. Work centers can be: Machines People Production lines The initial screen of the work center is given below. The T-Code to create work center is CR01.change CR02,DisplayCR03.
We have to enter the plant and name of the work center and work center category. Ex: Plant =7777 Name of the Work center: LRTM Work Center Category: 0001=machine,0003=Labor 65
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
We can copy work center from Different plants or in the same plant if they have got identical characteristics. Work Center is having 5 views. 1) basic data2) default values3) capacities4) scheduling and 5) costing The basic data screen as follows
We need to enter the description of work centered: RTM work center. Person responsible: the person who is responsible for that work center. Usage: Key to control in which type of Routings we use work centers. Here it is 009=all task list types. Standard value key: Key defining and giving a dimension (for example, time or area) to one of up to six standard values. We use the parameter ID to determine the key word for a standard value, such as setup, machine or labor. We assign values to the standard values in the task list.
66
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Default Values Screen
Control key: Determines which business transactions should be executed for the object that belongs to the routing or order. We have discussed about control key in routing, but if we tick in Ref.ID this is copied for an operation otherwise what is given in routing or task list is considered. No. of time tickets: Number of time tickets to be printed for an operation. This entry is only taken into account if time tickets are to be printed according to the operation control key. The value from the work center is the default in the routing. No. of Conformation slips: Number of confirmation slips to be printed for an operation or an activity. The system prints confirmations if the control key for the operation or activity has been set. The value from the work center is the default in the routing.
67
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Capacities
In capacities screen we have to enter the formulas for setup requirements, processing requirements and other requirements if necessary. The formulas you can find by using drop down menu .The capacity category we have to enter if it is the machine category or labor category. A machine can have labor capacity, (crew working on that machine)can be entered as additional capacity in the same view. We need to enter data in another screen for capacities.
68
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Capacity planner grp: Key referring to the capacity planner group, which is responsible for planning this capacity. Factory calendar ID: IN Active version: The active version of available capacity is used as a basis for scheduling. The different versions allow you to maintain several available capacities at the same time. Base Unit of measure: Unit in which available capacity is maintained Standard available capacity: We have to define the available capacity(start time, finish time ,length of breaks and no. of individual capacities).By entering these values we get standard available capacity. Planning details: We define whether the work center capacities are relevant to finite scheduling, can be used by several operations and for long term planning.
Scheduling
In the capacity category we enter the main category of the work center. Set up formula, processing formula: Here we assign formula in view of scheduling Location group: Define where this work center is located. 69
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Work dimension, Work Unit: Define work dimension and units of work as TIME and HR.
Capacities in scheduling:
Capacities relevant to scheduling point of view
70
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
COSTING
We have to assign the activity types and the relevant formulas for costing purpose.
71
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Reference operation set A type of routing that comprises of a series of operations that recur frequently. It is used to create a routing. A reference operation set cannot be used directly in production. A reference operation set has the same structure as a routing. We cannot assign a material to be produced to a reference operation set.
The T-Code to create reference operation set is CA11.
This is the default screen of the reference operation set. Group: Here we can assign numeric key if it is required to combine several task lists. Otherwise system will assign internal number automatically.
Click on header icon. System will display header for reference operation set.
72
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Group counter: This key and the task list group uniquely identify a routing. By default it is 1. We need to fill the task list description. Usage: Enter 1 for production. Status: Enter 4 for released (general). Enter the lot size if it is required and enter the unit of measure. After entering data in above fields click operations. The operations screen is similar as routing operations screen. After entering values in operations screen save the reference operation set. The message will be displayed as below. Reference operation set was saved with group (ex.) 50000014.
73
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Trigger Points A trigger point is an object that can be assigned to an operation in order to trigger a function. The T-code for creation of trigger points is CO31. Trigger points can trigger functions, If the status of an operation changes When an operation is confirmed, in this case the user decides whether the function is triggered. The default screen for creation of trigger points
We have to enter the name of the trigger point.
The following screen appears. 74
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
We have to enter Trigger point usage: Grouping (standard) trigger points by their usage can have the following advantages: It becomes easier to locate similar trigger points When you enter a usage, the system lists all standard trigger points that have the same usage. It can display the type of function behind the trigger point. Trigger point Group: A combination of standard trigger points. We have click on the usage whether it is for triggering functions or used as release stop indicator and also the function which is to be activated. In the pic. Trig point functions checkbox is ticked. It means when the trigger point is activated and creates order with reference. Enter the system status and click on the status change triggering function. Activate once indicator: Use this indicator to specify that the milestone function can only be triggered once. Put the cursor on create order with reference and click on parameters. You can find the below screen
75
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
We need to enter the system status, and status change as ‘+’,execute once indicator, group as well as group counter and order type as ‘Zp01’.(or any other rework order type). So when any order is partially confirmed the trigger point automatically triggers rework order or reference operation set depends on the setting what we have entered. If it triggers rework order the internal number assignment is done (the immediate no. of main production order is created with order type ZP01).We have to manually confirm the rework production order and goods movements and settlement is done for this to main production order.
76
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Production Resource Tools Production Resource/Tool (PRT) is a moveable operating resource used in production or plant maintenance. We can assign production resources and tools to the task lists and production orders for which they are required.
Creation of PRT: T-code CF01
Enter the PRT name. Press enter.
77
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
The screen follows
Enter the status as 03 =released for production Task list usage =009 Base unit of measure = EA Plant =7777 Location=0001 Grouping key =2000 for fixtures. And press defaults
78
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
You will see the following screen:
Enter control key =1 Quantity formula =SAPF01 Usage value formula =SAPF02 Ref.date for start = 01 Ref. date for finish =04
79
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Go to extras and formula constants and you will find below screen.
Enter the prt quantity and units as 2 nos and EA.
80
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Now we Closed these Movement Type:
These (202,309,521) movement type is effecting our financial data and a lot of problems occurred in Balance sheet.
81
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Check Vendor Schedules: We should check vendor schedules with this Tcode.
TCODE: ZOPENSHL
These materials should receive on 23.07.2012 from respected vendors.
82
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Manually Created Schedule Lines: TCODE: YSLC
83
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
In Scheduling Agreements Schedule Lines will be created by MRP. We closed manually creation of schedule lines in Vendor Scheduling Agreements.
We closed Manually Creation of Production Orders. TCODE - CO01 Closed. On the basis of Production plan MRP will create planned orders and users will convert these planned orders in Production Orders. If there is any change in production plan we will change production plan in SAP system and run MRP again for getting planned orders and Procurement schedule lines. TCODE: MD04
84
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Select PldOrd and convert it in Production Order.
User can convert total order qty.
Or User can convert PartConvProdOrder 85
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
86
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Scrap and rework doc TCODE: CO01
Order is created for 200 qty for 88912M68K00 Order conformation
87
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
TCODE: CO15
Order is confirmed with 145 Nos , rework of 33 nos and rejection or scrap of 22 nos as shown in below screen and reason for variance in order quantity is also entered. Save confirmation.
TCODE: MB31 GR is done for confirmed quantity only, that is 145 nos 88
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
System show the screen below as deficit of order quantity 55 nos, ignore this message.
After rework you can GR ( no conformation again) the quantity as shown below. Suzzest zero lines indicator as shown. Enter the rework order qty as 33 in the units of entry and save the order.
89
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Now the order quantity received is 178.
do GR in MB31 screen for 22 nos in scrap storage location.
90
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
The material in the Scrap store is scrapped by using 551 goods movement later in mb1a as below.
TCODE: MB1A (Movement Type is 551)
91
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
If you have created a Production orders and some change in BOM required. Engineering Department change in BOM and that change material are not effective in old production orders. This process will update BOM material in production orders after change in BOM. TCODE-CO02
Open production order in change mode.
92
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Go to Functions menu and Select Read PP master data.
93
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Click on check box “New BOM” and enter today’s date for explosion new/change BOM in production order.
94
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
SAP TCODES FOR PRODUCTION USERS TCODE MM03 MMBE MM60 CS03 CS11 CS12 CS13 CR01 CR02 CR03 CR11 CR12 CR13 CR05 CA80 CR15 CR10 CA01 CA02 CA03 CA12 CA13 MD61 MD62 MD63 MD4C
Description Display Material Stock Overview Material List Display Material BOM Explode BOM: Level by Level Explode BOM: Multi Level BOM Explode BOM: Summarized BOM Create Work Center Change Work Center Display Work Center Create Capacity Change Capacity Display Capacity Work Center List Work Center Where-Used Capacity Where-Used Work Center Change Document Create Routing Change Routing Display Routing Change Reference Operation Set Display Reference Operation Set Create Planned Independent Requirements Change Planned Independent Requirements Display Planned Independent Requirements Multilevel Order Report
95
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Evaluations MD04 MD07 MD05 MD06 CO46
Stock / Requirements List Collective access of stock / requirements list MRP List Collective access of MRP lists Order Progress
Planned Order MD11 MD12 MD13 MD16 MD14 MD15 MDVP CO01 CO07 CO40 CO41 CO08 COHV COMAC CO05N CO04N CO09 MB1A MB31
Create planned order Change planned order Display planned order Collective access of planned orders Individual conversion of planned order into Collective conversion of planned orders int Collective availability check Production order create (With Material) Production order create (Without Material) Production order create (From Planned Order) Collective convention of planned order Production order create (For Sales Order) Mass Processing Production Orders Collective Availability check Release Production Orders Print Production Orders Availability Overwiew Enter Goods Issue Goods Receipt for order
96
NTF Technik India Pvt. Ltd.
User Training Document
NTF (INDIA) PVT. LTD.
Reports COOIS
Order Information System
MCP7 MCP1 MCP5 MCP3 MCRE MCYJ CO20 CO21 CO22 CO23 CO24 CO27 CO28 CO26
Work Center Analysis Operation Analysis Material Analysis Production Order Analysis Material Uses Analysis Shop Floor Information System Orders Acc. to Order Number Orders for material Orders for MRP Controller Orders for Production Scheduler Missing Parts Info System Picking List Selection of Indiv. Objects List Order Information System
97
NTF Technik India Pvt. Ltd.
View more...
Comments
