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TSCM40_I Planning / Manufacturing I SAP ERP - Production

Date Training Center Instructors

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Instructor Handbook Course Version: 95 Course Duration: 10 Day(s) Material Number: 50099842 Owner: Frank Layer (D036000)

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

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

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About This Handbook

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

Unit 1: Course Overview ................................................. 1 Academy Overview .....................................................2

Unit 2: Overview of Master Data for Product Management and Manufacturing .............................................................. 9 Types of Data in SAP ERP .......................................... 11 Use of Organizational Data and Master Data in Production..... 20

Unit 3: Organizational Data in Supply Chain Management..... 37 Plants ................................................................... 38 Storage Locations..................................................... 45 MRP Areas............................................................. 53

Unit 4: Material Masters ................................................ 61 Overview of the Material Master .................................... 63 Creating a Material Master .......................................... 70 Classification of the Material Master ..............................102 Managing the Material Master......................................122

Unit 5: Bills of Material ................................................ 151 Overview of the Bill of Material .....................................152 Managing Bills of Material ..........................................167 BOM Reporting.......................................................195

Unit 6: Modeling the Manufacturing Process .................... 215 Modeling Manufacturing ............................................217 Basic Work Center Data and Defaults ............................224 Capacities in the Work Center .....................................245 Integrating Costing with the Work Center.........................257

Unit 7: Task Lists........................................................ 263 Overview of the Task List ...........................................265 Creating a Routing and Material Assignment ....................280 Suboperations and User-Defined Fields ..........................291 Reporting and Mass Changes......................................302

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Unit 8: Advanced Bill of Material Functions ...................... 321 Phantom Assemblies ................................................323 Co-Products and By-Products......................................328 Discontinuation and Substitute Parts in the Bill of Material.....336 Multiple and Variant BOMS .........................................352 Mass Changes and the Product Structure Browser .............376

Unit 9: Advanced Routing Functions .............................. 387 Modeling Complex and Flexible Manufacturing Processes ....389 Modeling Alternative Manufacturing Processes..................400 Reference Operation Sets ..........................................412 Lead Time Scheduling and Material Master Updates ...........423 Time Components, Reduction Possibilities in the Routing .....432 Trigger Points in the Routing .......................................448 Scrap and Its Effects ................................................456 Production Resources/Tools........................................472

Unit 10: Alternative User Interfaces ................................ 485 Structure of the Engineering Workbench .........................487 Navigating in the Engineering Workbench .......................494 Engineering Workbench Work Areas..............................512 Introduction to the PLM Web User Interface .....................526

Unit 11: Appendix ....................................................... 549 Configuration of the Material Master ..............................551 Configuration of the Bill of Material ................................574 Configuring the Work Center ......................................590 Configuring the Routing .............................................622

Index ....................................................................... 635

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Course Overview The course TSCM40 teaches you how to work with master data (course week 1) and production planning (course week 2) in SAP ECC. The course material therefore consists of two course books: TSCM40_I and TSCM40_II. This course book TSCM40_I only deals with the content of the first week of TSCM40. The second week is covered by the course book TSCM40_II.

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

Application consultants responsible for the implementation of planning as part of the SAP Business Suite in SAP ERP.

Course Prerequisites Required Knowledge • • • • •

SAP125 – SAP Navigation 2005 (e-learning) TERP01 – SAP ERP: Introduction (e-learning) TERP02 – SAP ERP: Introduction to SAP NetWeaver (e-learning) TERP51 – SAP ERP: Introduction to Processes in Material Planning (e-learning) TERP52 – SAP ERP: Introduction to Processes in Manufacturing Execution (e-learning)

Recommended Knowledge •

No additional knowledge required

Course Duration Details Unit 1: Course Overview Academy Overview

10 Minutes

Unit 2: Overview of Master Data for Product Management and Manufacturing 30 Minutes Types of Data in SAP ERP Use of Organizational Data and Master Data in 45 Minutes Production Unit 3: Organizational Data in Supply Chain Management 20 Minutes Plants

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Course Overview

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Storage Locations MRP Areas Unit 4: Material Masters Overview of the Material Master Creating a Material Master Exercise 1: Creating Material Masters Classification of the Material Master Exercise 2: Material Classification Managing the Material Master Exercise 3: Managing Material Masters

30 Minutes 45 Minutes 40 Minutes 30 Minutes 15 Minutes 45 Minutes 20 Minutes

Unit 5: Bills of Material Overview of the Bill of Material Exercise 4: BOM Basics Managing Bills of Material Exercise 5: Changing Bills of Material BOM Reporting Exercise 6: Multilevel BOM Reporting

45 Minutes 20 Minutes 45 Minutes 40 Minutes 20 Minutes 15 Minutes

Unit 6: Modeling the Manufacturing Process Modeling Manufacturing Basic Work Center Data and Defaults Exercise 7: Create a Work Center Capacities in the Work Center Exercise 8: Capacities in the Work Center Integrating Costing with the Work Center

30 Minutes 30 Minutes 15 Minutes 45 Minutes 15 Minutes 20 Minutes

Unit 7: Task Lists Overview of the Task List Exercise 9: Create a Simple Routing Creating a Routing and Material Assignment Exercise 10: Material Assignment and Component Allocation Suboperations and User-Defined Fields Exercise 11: Suboperations for Material-Specific Capacity Constraints Reporting and Mass Changes Exercise 12: Task List Changes with ECM Unit 8: Advanced Bill of Material Functions Phantom Assemblies Co-Products and By-Products Exercise 13: Co-Products in Production Orders Discontinuation and Substitute Parts in the Bill of Material Exercise 14: Substitute Items in Production Orders Multiple and Variant BOMS

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20 Minutes 15 Minutes

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20 Minutes 20 Minutes 30 Minutes 15 Minutes 25 Minutes 10 Minutes 15 Minutes 20 Minutes 30 Minutes 15 Minutes 20 Minutes 30 Minutes 20 Minutes 40 Minutes

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Course Overview

Exercise 15: Multiple/Alternative Bills of Material Exercise 16: Variant BOMs Mass Changes and the Product Structure Browser Exercise 17: Mass Changes and the Product Structure Browser Unit 9: Advanced Routing Functions Modeling Complex and Flexible Manufacturing Processes Exercise 18: Creating Alternative and Parallel Sequences Modeling Alternative Manufacturing Processes Exercise 19: Creating Alternative Routings and Production Versions Reference Operation Sets Exercise 20: Reference Operation Sets Lead Time Scheduling and Material Master Updates Exercise 21: Scheduling Time Components, Reduction Possibilities in the Routing Exercise 22: Time Elements of the Operation in Scheduling Trigger Points in the Routing Scrap and Its Effects Exercise 23: Scrap in Production Production Resources/Tools Exercise 24: Creating and Assigning PRTs Unit 10: Alternative User Interfaces Structure of the Engineering Workbench Navigating in the Engineering Workbench Exercise 25: Navigating in the EWB Exercise 26: Navigating in the EWB II Engineering Workbench Work Areas Exercise 27: Create a Work Area Introduction to the PLM Web User Interface Exercise 28: Using the PLM Web User Interface Unit 11: Appendix Configuration of the Material Master Exercise 29: Material Types, Field Control and Material Status Configuration of the Bill of Material Exercise 30: Bill of Material Configuration Configuring the Work Center Exercise 31: Work Center Category and Field Selection Control, Default Work Center (Optional) Exercise 32: Optional: Work Center Formulas

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15 Minutes 20 Minutes 20 Minutes 10 Minutes

20 Minutes 20 Minutes 20 Minutes 30 Minutes 20 Minutes 20 Minutes 30 Minutes 20 Minutes 30 Minutes 30 Minutes 30 Minutes 25 Minutes 20 Minutes 20 Minutes 10 Minutes 40 Minutes 45 Minutes 30 Minutes 35 Minutes 20 Minutes 20 Minutes 30 Minutes 20 Minutes 60 Minutes 30 Minutes 30 Minutes 15 Minutes 45 Minutes 20 Minutes 30 Minutes

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Course Overview

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Configuring the Routing

45 Minutes

Course Goals This course will prepare you to: • •

Understand the general handling of logistics master data in SAP ECC Understand and describe the positioning, integration, and functions of the planning area within the SAP ERP application

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

Use the relevant master data elements for the modelling of planning and production processes Evaluate, describe, and implement the options provided by SAP-ERP-based planning

•

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

SAP ERP Central Component 5.0 SAP ERP Central Component 6.05

Important Information It is strongly recommended to check necessary information published on the SAP Service Market Place. All information essential for course preparation like instructor guides, system setup guides, trouble shooting guides, logon information, and so on, you will find under the alias /curr-info (http://service.sap.com/curr-info). In case you cannot access this site please ask the responsible education coordinator (the sender of this document) to make the relevant information available to you.

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Unit 1 Course Overview

1

Welcome the participants to the first week of the course and introduce yourself and briefly the overall course content and objectives. Familiarize the participants with the course schedule. Ask the participants to introduce themselves.

Unit Overview The academy course TSCM40 operates exclusively within SAP ECC as far as content, demonstrations, and exercises are concerned, dealing with the master data background and production planning process in the system. The course builds on the basics contained in the according e-learning sessions. As an introduction, the course contents are outlined.

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

Give an overview of the scope of the training

Unit Contents Lesson: Academy Overview......................................................2

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Lesson:

Academy Overview

2

Lesson Duration: 10 Minutes

Lesson Overview This lesson provides an overview of the training required for the Application Associate Planning & Manufacturing with SAP ERP 6.0.

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

Give an overview of the scope of the training

Provide the participants with a brief overview of the academy course. Refer to the e-learning courses that the participants should already have attended.

Business Example Basic Training The training courses TSCM40 (Planning/Manufacturing I) and TSCM42 (Planning/Manufacturing II (including case study)) provide the participants with knowledge of the business processes of planning and manufacturing in a basic training geared towards manufacturing companies. In the training course TSCM40 (Planning/Manufacturing I), you learn about the master data required for production (material masters, bills of material, work centers, routings, etc.), including master data management, as well as about the concepts and business processes of selected planning areas. The course deals with the processes of production planning using material requirements planning (ERP-PP-MRP module), as well as the different planning strategies for creating a master plan. The course also demonstrates evaluation methods for evaluating the planning results. The follow-up training course TSCM42 (Planning/Manufacturing II (including case study)) teaches you the different options for controlling production. This includes order-based production with production orders or process orders, repetitive manufacturing, and Kanban. These options provide effective support for the complete manufacturing process including the process steps of material staging, sequencing, creation of shop floor papers, confirmation, goods receipt, and settlement of production activities. The focus is set on production order management. An overview is provided of the other options named above.

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Lesson: Academy Overview

Moreover, the training course also contains a summary of capacity planning as well as a case study. The latter allows you to apply the knowledge you have acquired by configuring specified integrated business processes. The training course ends with an exam (certification C_TSCM42_65). The following diagram provides an overview of the scope of the training.

Figure 1: Consultant Profile Application Associate - Planning & Manufacturing with SAP ERP 6.0: Basic Training

Alternative project team training The training materials for the Solution Academy are predominantly based on the corresponding standard training course, but are supplemented by topics that are relevant for consultants. The following table shows the topics that were taken from the standard training course and the topics that are dealt with in addition: Note that the e-learning courses are not included in this overview.

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Unit 1: Course Overview

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Solution Academy Training

Course Content

TSCM40 (Planning/Manufacturing I)

5 days PLM114 (Basic Data) 5 days SCM240 (Production Planning (ERP))

TSCM42 (Planning/Manufacturing II (incl. Case Study))

4.5 days SCM310 (Production Orders) 0.5 days KANBAN from SCM300 (Production Overview) 1 day from SCM365 (Capacity Planning (ERP)) 1 day Repetitive Manufacturing and Process Manufacturing from SCM300 (Production Overview) 2.5 days Integrated Case Study (academy only!) 3 hours Certification Exam C_TSCM42_65

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Lesson: Academy Overview

Facilitated Discussion Optional

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

Ask the customers who is intending to take the Certification Exam.

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Lesson Summary You should now be able to: • Give an overview of the scope of the training

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Unit Summary

Unit Summary You should now be able to: • Give an overview of the scope of the training

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Unit Summary

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Unit 2 Overview of Master Data for Product Management and Manufacturing

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This unit is designed as an introduction to the use of master data in production planning and execution in SAP ERP. Participants might have taken SCM100/SCM300 or SCM130 to have a more detailed overview of the Planning and execution functions in SAP ERP. This section is designed as a refresher for those participants and enlighten participants who have not taken the necessary prerequisites.

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

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

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

Unit Contents Lesson: Types of Data in SAP ERP ........................................... 11 Demonstration: Configuration in SAP ERP .............................. 12 Procedure: Configuring SAP ERP ........................................ 14 Demonstration: Production Planning Master Data ...................... 15 Demonstration: Transactional Data ....................................... 16

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Lesson: Use of Organizational Data and Master Data in Production ..... 20 Demonstration: Organizational Structures in SAP ERP................ 25 Demonstration: Views and Fields in the Material Master .............. 28 Demonstration: BOMs ...................................................... 29 Demonstration: Work Centers ............................................. 31 Demonstration: Routings ................................................... 32

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Lesson: 8

Lesson: Types of Data in SAP ERP

Types of Data in SAP ERP Lesson Duration: 30 Minutes

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

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

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

This section is designed for true beginners. If you have an experienced class, gloss over the material at high level. This will be an introduction to configuration.

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

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

Configuration data Master data Transactional data

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

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Figure 2: Configuration in SAP ERP

During an implementation, the SAP ERP landscape will typically consist of three servers: DEV (development), QA (quality assurance), and PROD (production). Each server may have several clients. The DEV server is where a sandbox client will exist, as well as the golden client, where the final configuration resides. During the project, team members will try different iterations of configuration in the sandbox client and test the results. If the results meet the organizations requirements, they are configured again in the golden client. From there, the Basis team moves it to the QA server for further evaluation. The Basis team will us a tool called the Change and Transport System (CTS). This allows them to track the configuration changes from DEV to QA, and QA to PROD. Once the configuration changes are moved to the QA server, integration testing will take place within the PP module and within the other applications in SAP ERP, such as materials management (MM) and Sales and Distribution (SD), for example. Once fully tested in the QA system, the configuration will be transferred to PROD, or the production server/client.

Demonstration: Configuration in SAP ERP Purpose Show New Project Team members how to Access IMG

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Lesson: Types of Data in SAP ERP

System Data System: Client: User ID: Password: Set up instructions: 1. Show students Transaction code SPRO. Do not bother to show menu path as it seems to change for every new release.

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2.

Select Reference IMG

3.

follow menu path : Production → Basic Data → Bill of Material → Control Data for Bill of Material → Define Default Parameters

4.

Explain Configuration

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Configuring SAP ERP 10

1.

Enter transaction code SPRO.

2.

Select Reference IMG.

3.

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

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

Figure 3: Master Data

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

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

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Lesson: Types of Data in SAP ERP

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

Demonstration: Production Planning Master Data Purpose

System Data System: Client: User ID: Password: Set up instructions: 1. Show users the menu paths they will be using over the next several days. 2.

Follow Menu path : Logistics → Production → Master Data

3.

Point out the folders for the material master, Bill of material, Work Center and Routing.

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

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Figure 4: Transactional Data

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

Demonstration: Transactional Data Purpose Demonstrate creating a production order and the need for master data

System Data System: Client: User ID: Password: Set up instructions: 1. Follow menu path: Logistics → Production → Production Control → Order → Create → With Material

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Lesson: Types of Data in SAP ERP

2.

Enter material T-F200, plant 1000, order type PP01. Select Enter

3.

Enter 10 pcs and enter a finish date of on month from today. Select Enter

4.

Show customers the Material master , Bill of Material, Routing and work centers.

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Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson: Types of Data in SAP ERP

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

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Lesson: 13

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Use of Organizational Data and Master Data in Production Lesson Duration: 45 Minutes

Lesson Overview In this lesson you will be exposed to organizational data and its potential impact on production planning in SAP ERP.

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

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

This lesson is designed for new customers that have never worked SAP ERP or production planning. If class participants are knowledgeable in SAP ERP use this as an overview and move through the material quickly. Note: We have included information about other application organizational levels as students will come across the objects within the PP master data. It is collateral information only. If they wish to know more about SD organizational structures suggest SCM600. If they wish to know more about MM organizational Structures suggest SCM500.

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

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

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Lesson: Use of Organizational Data and Master Data in Production

Figure 5: Organizational Structure

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

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Company code A company code is the smallest organizational unit of external accounting for which a complete, self-contained bookkeeping system can be replicated. This includes the entry of all events that require posting to the accounts and the creation of a complete audit trail for balance sheets and profit-and-loss statements. A company code represents an independent unit producing its own balance sheet, for example, a company within a corporate group (client). You can set up several company codes in one client in order to keep separate sets of financial books. You can use a special Customizing function to copy a company code. In the process, company-code-dependent specifications are adopted for your new company code. A company code is defined in the system by means of a four-character alphanumeric key that is unique in the client. Plant The plant is an organizational unit within logistics that subdivides an enterprise from the viewpoints of production, procurement, and materials planning. Storage Location The storage location is an organizational unit that facilitates the differentiation of stocks of materials within a plant. Inventory management on a quantity basis is carried out in the plant at storage-location level. The physical inventory is also carried out at this level. A storage location is defined by means of a four-character alphanumeric key that is unique in the plant. Organizational units are tightly linked to each other to quickly process the relevant data for a business area. For example: Plant

1000 is assigned to

company code

1000

Company code

1000 is assigned to

controlling area

1000

Therefore, whenever a transaction involving cost occurs in plant 1000, the relevant records in controlling area 1000 are automatically updated. The valuation area is the organizational level at which material quantities and values are managed. It is essential for product costing that a valuation area exists for each plant. Within each valuation level, you can differentiate between values and quantities for valuation (in-house production and external procurement) by using different valuation types. In Customizing for materials management (define valuation type), balance sheet valuation is set up at company-code or valuation-area level. Selection of valuation-area level automatically causes the creation of a valuation area for each plant. To use product costing and order costing, inventory must be valuated at plant level.

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Lesson: Use of Organizational Data and Master Data in Production

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

Figure 6: Purchase Organization

A purchasing group is a key for a buyer or a group of buyers who are responsible for certain purchasing activities. Internally, the purchasing group is responsible for the procurement of a material or class of materials. Externally, it is the principal channel for an enterprise’s dealings with its vendors. Note: The purchasing group is not assigned to other units of the enterprise structure in SAP ERP. Purchasing groups are not defined in Customizing for the enterprise structure, but in Customizing by choosing Materials Management → Purchasing → Create Purchasing Groups. The purchasing organization is an organizational unit within logistics that subdivides the enterprise according to the purchasing requirements. A purchasing organization procures materials or services, negotiates conditions of purchase with vendors, and assumes responsibility for these transactions.

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

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

Figure 7: Sales Organization

The sales organization is responsible for selling and distributing goods and services. It is liable for the products sold and responsible for a customer’s rights of recourse. The sales organization can be used to represent a regional, national, or international subdivision of a marketplace in which products are sold. A sales organization is uniquely assigned to a company code, however a company code may have more than one sales organization assigned to it. If the Sales and Distribution module is used, at least one sales organization must be defined. The sales organization is the highest summation level in sales statistics. Customer master data will be created for each sales organization. Documents created throughout the Sales and Distribution process (order, delivery, and billing document) will belong to a sales organization.

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Lesson: Use of Organizational Data and Master Data in Production

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

Restricted price agreements to a certain division Statistical analysis by division

A sales area is a unique and allowable combination of a sales organization, distribution channel, and division. Each Sales and Distribution document is assigned to exactly one sales area. This assignment cannot be changed. A sales area can belong to only one company code. This relationship is created by the assignment of the sales organization to the company code in Customizing. The shipping point is the organizational element that manages your shipping activities. Each outbound delivery is processed at a shipping point. A shipping point can be a physical location, for example, a loading dock, a mail room, or a railroad depot. It can also be a logical location, for example, a group of employees responsible for processing next-day deliveries or less-than-truckload orders. Shipping points are assigned to plants. A shipping point should have physical proximity to the plant to which it is assigned. More than one shipping point can be assigned to a plant. Several plants can also have a shared shipping point assigned to them, for example, several plants in same physical proximity sharing the same railroad depot.

Demonstration: Organizational Structures in SAP ERP Purpose Show participants how org structures are assigned.

System Data System: Client: User ID:

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Unit 2: Overview of Master Data for Product Management and Manufacturing

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Password: Set up instructions: 1. Follow Menu Path: SPRO → Enterprise Structure → Assignment → Logistics-General → Assign Plant to Company Code → 2.

Assign Business Area to Plant/Valuation Area...

3.

SPRO → Enterprise Structure → Assignment → Sales and Distribution → Assign Sales Org to Company Code...

4.

SPRO → Enterprise Structure → Assignment → Materials Management → Assign Purchasing Org to Company Code...

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

Figure 8: Master Data for Production Planning

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Lesson: Use of Organizational Data and Master Data in Production

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

Material master Bill of material Work center Routing/task list

Material Masters Material Master Record: Definition The material master contains information on the materials that a company constructs, procures, manufactures, stores, and sells. The information is stored in a database that is a central source of data on materials. The material master record integrates data from different areas of a company.

Figure 9: Material Masters in SAP ERP

For the company, the material master record represents the central source for data on materials. The material master is used by various SAP logistics applications. The material can be a finished product (product or article), a semi-finished product (subassembly), or a raw material (purchased part).

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Demonstration: Views and Fields in the Material Master Purpose Demonstrate the material master

System Data System: Client: 8## User ID: Password: Set up instructions: P-100 in plant 1000 1. Show material P-100 in plant 1000. Follow menu Path: Logistics → Production → Master Data → Material Master → Material → Change → Immediately

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

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Lesson: Use of Organizational Data and Master Data in Production

Figure 10: Bills of Material In SAP ERP

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

Demonstration: BOMs Purpose In the BOM P-100 show the BOM header and the components with their item categories.

System Data System: Client: User ID:

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Password: Set up instructions: 1. In the BOM P-100 show the BOM header and the components with their item categories. Show material P-100 in plant 1000. Follow menu Path: Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change

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

Figure 11: Work Centers in SAP ERP

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

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Lesson: Use of Organizational Data and Master Data in Production

Demonstration: Work Centers Purpose Where to find work centers.

System Data System: Client: 8## User ID: Password: Set up instructions: 1. Show Work Center 1310 in plant 1000. Follow menu Path: Logistics → Production → Master Data → Work Center → Work Center → Change

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

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

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Figure 12: Routings in SAP ERP

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

Lead time scheduling Product costing Capacity planning

Demonstration: Routings Purpose

System Data System: Client: User ID: Password: Set up instructions:

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Lesson: Use of Organizational Data and Master Data in Production

1.

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Show Routing P-100 in plant 1000. Follow menu Path: Logistics → Production → Master Data → Routings → Routings→ Standard Routing → Change

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Facilitated Discussion Perform overview of lesson.

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions. • •

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What are the PP-relevant organizational elements? Describe how master data objects are dependant on one another.

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Lesson: Use of Organizational Data and Master Data in Production

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

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Unit Summary

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

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Unit 3 Organizational Data in Supply Chain Management

27

In this lesson you will introduce the participants to the concepts of configuration and the IMG. This lesson is designed to be as informative to new users and a refresher for experienced users.

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

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

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

Unit Contents Lesson: Plants ................................................................... 38 Demonstration: Configuration of a Plant ................................. 40 Procedure: Configuring a Plant............................................ 42 Lesson: Storage Locations ..................................................... 45 Demonstration: Configuration of a Storage Location ................... 48 Procedure: Configuring a Storage Location ............................. 50 Lesson: MRP Areas ............................................................. 53 Demonstration: Configuring and Using an MRP Area .................. 55 Procedure: Using MRP Areas ............................................. 57

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Plants Lesson Duration: 20 Minutes

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

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

Describe the purpose of a plant in SAP ERP

In the past this course has never expanded on organizational structures. The point of this unit is to show participants how important the plant is, especially the plant calendar since it will affect both order scheduling and Planned independent requirements (forecast)

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

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

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Lesson: Plants

Figure 13: Definition of a Plant

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

Figure 14: Plant in the Organizational Structure

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When creating a new plant, you can use the plant copy function. In the process, all entries in the plant table and all Customizing and system tables that depend on it (and in which the plant occurs as the key) are taken into account. A plant is defined in the system by means of a four-character alphanumeric key that is unique in the client. Once a plant is configured, it must be assigned to several other organizational elements to assure cross-functional integrations. Here is an example of where the plant will be assigned: • • • •

Company code Business area Sales organization Purchasing organization

Plants are often determined as single geographical locations where those necessary business functions must be tracked. In certain situations, companies can combine several locations that are closely geographically located into one plant to minimize the organizational hierarchy. Due to tax reasons, some companies will split a single location into multiple plants. For example, companies will sell their finished goods to another company immediately after production, while the distribution location belongs to another facility. Both plants may exist in the same geographical location, but remain as two separate plants reporting to two separate company codes. As mentioned earlier, the plant is the key focal point for production planning. All master data, planning, and execution activities are defined and performed the plant level. Some examples of these dependencies are: • • • • • • •

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

Demonstration: Configuration of a Plant Purpose Create a Plant

System Data System: Client:

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Lesson: Plants

User ID: Password: Set up instructions: 1. Demonstrate the configuration of a plant. Follow IMG Menu Path: Enterprise Structure → Definition → Logistics-General → Define, copy, delete, check plant 2.

Select Define Plant. Select Plant 1000 and select

Details

Note: Point out the Factory Calendar that is assigned to the plant. Inform participants that this calendar will affect order scheduling and demand during planning. 3.

Select Back twice to the pop-up window and select Copy, delete, check plant.

4.

Select

5.

Enter Copy From 1000 and copy to P114 and select

6.

Once completed exit to the main menu and demonstrate the following IMG transactions

7.

IMG Menu Path: Enterprise Structure → Assignment → Logistics-General → Assign plant to company code

Copy Org. Object Continue (Enter)

Review Company code 1000 Note: Plant P114 has been assigned to company code 1000. 8.

IMG Menu Path: Production → Shop Floor Control → Master Data → Order → Define Order-type Dependent Parameters Select Position and enter plant P114

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Configuring a Plant 31

1.

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

2.

Choose Define Plant. Select Plant 1000 and choose

3.

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

4.

Choose

5.

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

6.

Once completed, exit to the main menu.

7.

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

Details.

Copy Org. Object.

Review Company code 1000. Note: Plant P114 has been assigned to company code 1000. 8.

Choose Enterprise Structure → Assignment → Logistics-General → Assign plant to company code. Review Company code 1000. Note: Plant P114 has been assigned to company code 1000.

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Lesson: Plants

Facilitated Discussion Lesson Review

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions. •

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Why are plants important to Production planning?

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

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Lesson: 33

Lesson: Storage Locations

Storage Locations Lesson Duration: 20 Minutes

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

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

Describe the purpose of a storage location in SAP ERP

In previous versions of this class storage locations were never given much consideration. The group responsible for inventory management will typically control these. However, manufacturing will decide if backflushing is done or MRP Areas will be needed. This requires participants to have a more thorough understanding of storage locations in SAP ERP.

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

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

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Figure 15: Storage Locations in SAP ERP

As with all organizational elements, storage locations are configuration and are defined in the IMG. A storage location is defined by means of a four-character alphanumeric key that is unique in the plant. The enterprise structure is created through the assignment of organizational levels to each other. A client may therefore contain several company codes. In turn, a company code may contain several plants. However, a plant can only ever belong to one single company code in the SAP system. Hint: Since the plant key is unique in a client, and a plant can only belong to one company code, by specifying the plant you simultaneously specify the company code. Several storage locations may be assigned to a plant, but when a certain storage location is assigned to a plant it forms a compound key. Storage locations are defined especially for a plant and are thus assigned to this plant. The storage location key need only be unique within a plant. Within a client, the same key can be used for different storage locations, since when you specify a storage location you always have to specify the plant as well.

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Lesson: Storage Locations

Figure 16: Storage Location Address

Note: To create storage locations, in the IMG, choose Enterprise Structure → Definition → Materials Management → Maintain Storage Location. Here you can create a storage location in reference to a plant. Upon creating a storage location, you will define a unique four-character value. This value is alphanumeric, so a company could create an exhaustive number of storage locations for each facility. In addition, when creating a storage location, companies have the opportunity to define a different address for each storage location. This may be done for one of several reasons: • •

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

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

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The material master record is automatically extended the first time a goods receipt is posted for the material. All data specific to the storage location is updated in the material master record. The system can be configured in this way in Customizing by choosing Materials Management → Inventory Management and Physical Inventory → Goods Receipt → Create Storage Location Automatically. In this step, you specify whether the automatic creation of storage location data is allowed for goods receipts. This is advisable if you want to post a goods receipt without having to maintain the storage location view of the material master record in advance. First, you have to allow automatic creation per plant. You then have to explicitly allow the creation of storage location data for each movement type. The storage location data is only created if the quantity is posted to “standard” storage location stock. It is not created for receipts into a special stock (for example, into sales order stock). Note: The standard system is set in such a way that the storage location data is created automatically for all types of receipts (goods receipt with or without reference, stock transfers, initial entry of stock balances, reversal of goods issues, and so on). To manually create storage locations, enter the storage locations for a material master record collectively. This is much less time-consuming than entering the data for each storage location individually. This can be performed from the application menu path by choosing Logistics → Production → Master Data → Material Master → Other → Enter Storage Locations (MMSC). Once a material exists in a storage location users, will see a Storage location view on the material master. In addition, they will be able to make settings for material requirements planning (MRP) at the storage-location level in the MRP 4 view.

Demonstration: Configuration of a Storage Location Purpose Demonstrate to Participants how to create a new Storage location for your plant P114

System Data System: Client: User ID: Password: Set up instructions: 1. To create storage locations follow the IMG menu path: Enterprise Structure → Definition → Materials Management → Maintain Storage Location. 2.

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Choose

Execute

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Lesson: Storage Locations

3.

Enter Plant P114

4.

Choose New Entries

5.

Enter the storage location number OS01, and a description of Off Site 1

6.

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

7.

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

8.

Choose

Save

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Configuring a Storage Location 37

50

1.

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

2.

Choose

3.

Enter Plant P114 and choose

4.

Choose New Entries.

5.

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

6.

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

7.

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

8.

Choose

Execute. Continue.

Save.

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Lesson: Storage Locations

Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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

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Lesson: 39

Lesson: MRP Areas

MRP Areas Lesson Duration: 15 Minutes

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

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

Describe the purpose of an MRP area in SAP ERP

This lesson is to be position to the participants as a possible alternative to modeling multiple plants within a given location. For example a ship yard may be laid out over several square kilometers/miles, with various buildings. Instead of each building being a plant, MRP areas May be an alternative to creating multiple plants. Note: MRP Areas are only related to planning, so they have no financial impacts If more information is required, direct students to the online help or SCM240.

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

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

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Note that MRP areas are not part of the standard org structure. However they will use storage locations as part of their definition. This may lead to creating addition storage locations to use with MRP Areas, than what was previously decided.

Figure 17: Organizational Structure Overview

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

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Lesson: MRP Areas

Figure 18: MRP Areas

MRP areas are defined as part of MRP configuration. There are three types of MRP areas: plant, storage location, and Vendor (subcontractor). We will only focus on the storage location aspect since that can affect the modeling of your organizational structure. Note: To find MRP Areas in the IMG, choose Production → Materials Requirements Planning → Master Data → MRP Areas → Define MRP Areas. When creating MRP areas, you must specify the MRP area type, plant, and receiving storage location for Type 2 (storage location). Companies have the options of assigning one or more storage locations to each MRP area. Once an MRP area is defined, users must assign material masters to the MRP areas they wish to segregate from the rest of the plant. Note: When demand is placed at the storage location level – either through sales order, demand management, or via some dependent demand – if the material master is assigned to an MRP area that contains the storage location, all demand and inventory are kept separate from the plant.

Demonstration: Configuring and Using an MRP Area Purpose

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System Data System: Client: User ID: Password: Set up instructions: 1. IMG Menu path to MRP Areas: Production → Materials Requirements Planning → Master Data → MRP Areas → Define MRP Areas 2.

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Select New Entries Field

Value

MRP Area

OS01-P114

Description

Out Sided Storage

MRP Area Type

02 - Storage Location

Plant

P114

3.

Press Enter

4.

Enter receiving storage location OS01, and select

5.

From the application menu follow: Logistics → Production → Master Data → Material Master → Material → Change → immediately

6.

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

7.

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

© 2010 SAP AG. All rights reserved.

Save

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Lesson: MRP Areas

Using MRP Areas 42

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1.

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

2.

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

Value

MRP Area

OS01-P114

Description

Out Sided Storage

MRP Area Type

02 - Storage Location

Plant

P114

3.

Press ENTER.

4.

Enter receiving storage location OS01and choose

5.

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

6.

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

7.

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

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Save.

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Facilitated Discussion Review why a company might use MRP areas instead of plants.

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson: MRP Areas

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

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

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Unit Summary

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

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Unit 4 Material Masters

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In this unit you will demonstrate to the participants the different phases of a material masters life cycle. This will include, creation, updates, and deletion. In this unit you will create several material masters that will be used in the bill of material lessons.

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

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

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

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Unit Contents Lesson: Overview of the Material Master..................................... 63 Demonstration: Organizational Levels of the Material Master......... 66 Procedure: Organizational Levels of the Material Master .............. 67 Lesson: Creating a Material Master ........................................... 70 Demonstration: Prerequisite for Creating Material Master ............. 77 Demonstration: Setting Up Defaults ...................................... 80 Demonstration: Creating a Material from Scratch....................... 81 Demonstration: Setting Up MRP Profiles ................................ 82 Exercise 1: Creating Material Masters.................................... 87 Lesson: Classification of the Material Master ...............................102 Demonstration: Updating the Material Master ..........................103 Demonstration: Demonstrate Set up of Classification .................106 Demonstration: .............................................................108 Demonstration: Demonstrate Batch classification of the material Master ........................................................................ 110 Demonstration: Demonstrate variant configuration of the material master ........................................................................ 113 Exercise 2: Material Classification ....................................... 115 Lesson: Managing the Material Master ......................................122 Demonstration: Extending the Material Master.........................124 Demonstration: Changing the Material Type............................125 Demonstration: Change Material Master MM02 .......................126 Demonstration: .............................................................128 Demonstration: Demonstrate Updating Material Masters with Mass Maintenance.................................................................130 Demonstration: Demonstrate Archiving the Material Master .........134 Exercise 3: Managing Material Masters .................................139

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Lesson: 47

Lesson: Overview of the Material Master

Overview of the Material Master Lesson Duration: 30 Minutes

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

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

Describe the organizational layout of the material master

This lesson is designed to be an overview for the material master to gain introduce them to a specific topic. The important element of this lesson is to ensure students know the data exists in multiple tables and are attached to organizational structures.

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

Introduction to the Material Master The material master contains information on the materials that a company constructs, procures, manufactures, stores, and sells. The information is stored in a database that is a central source of data on materials. The material master record integrates data from different areas of a company.

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Figure 19: The Material Master

For a company, the material master record represents the central source for data on materials, and is used by various SAP logistics applications. The material can be a finished product (product or article), a semi-finished product (subassembly), or a raw material (purchased part). The material master can be valid for many different areas within the business. All data is maintained in several centralized tables, based on relevance to the particular part of the organizational structure. The material master is used by all SAP R/3 logistics applications. It controls whether a material is purchased, produced, or sold. Every area of responsibility can have a material master view. Because different user departments in a company work with the same material, and each of these departments wants to store different information on the material, you can subdivide material master data according to the department to which it belongs. Each department then has its own material master record view and is responsible for the data being correct. The data that you maintain in the following views is used by production planning (PP) functions: • • • •

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

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Lesson: Overview of the Material Master

Figure 20: Organizational Levels of the Material Master

Some material data is valid on all organizational levels and other data is only valid for specific levels. So that the material data can be managed centrally in the company without clogging up your data with redundant information, the material master is structured hierarchically, reflecting a company’s structure. In SAP ERP, the only elements that directly impact production planning are client, plant, and storage location. 
General material data that applies to the whole company is stored on client level. This includes material descriptions, base units of measure, and conversion factors for alternative units of measure. This data is contained in the table MARA. 
All data that applies to a plant and its assigned storage locations is stored on plant level. Examples of this kind of data are MRP and forecasting data. This data is contained in the table MARC. 
All data that applies to a specific storage location is stored on storage location level. This is mainly storage location stock. This data is contained in the table MARD.

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

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

Demonstration: Organizational Levels of the Material Master Purpose

System Data System: Client: User ID: Password: Set up instructions: 1. Follow menu path:Logistics → Production → Master Data → Material Master → Material → Change → Immediately

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2.

Enter P-100, and select only the Basic Data 1 View. Point out to participants no Org data was requested since it is at the client level.

3.

Select the MRP 1 Screen and enter plant 1000. Point out to participants that the system is asking for Org Data.

4.

Select the Plant data/stor. 1 tab and point out the request for storage location. Enter 0002

5.

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

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Organizational Levels of the Material Master 51

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1.

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

2.

Select the MRP 1 screen and enter plant 1000.

3.

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

4.

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

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Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson: Overview of the Material Master

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

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Creating a Material Master Lesson Duration: 45 Minutes

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

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

List the prerequisites to creating material masters Use various methods to create material masters Describe the request process with interactive forms and explain how it might benefit your business

This lessons is supposed to introduce participants in how to create material masters. You will need to show them how to create them efficiently and the different tips and tricks that are available.

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

Prerequisites for Creating Material Masters Prior to creating a material master, several pieces of information must be known in order to properly create a material master record in SAP ERP. The person who creates the first view of each material master record must define: • • • • •

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

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Figure 21: Material Types in SAP ERP

When you create a material master record, you must define material type for the material. The material type determines which business processes (such as sales, production, or purchasing) and functions (use of material in BOM or routing) are allowed for a material. The selection of the material type should not be taken lightly, as a wrong choice can have serious impacts. The material type is a configurable item and is usually controlled by costing or Inventory Management due to the large impact is has on those areas of an implementation.

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Figure 22: Material Type Configuration

To be able to manage different materials according to the company’s standard requirements, materials with the same characteristics are divided into groups and assigned to a material type. Examples of material types are raw materials, semi-finished products, and finished products. When you create a material master record, the material type determines: • • • • • • •

Which departments can maintain the material master record Whether the material number is assigned internally or externally Which number range interval the material number comes from Which screens appear and in which sequence Which department-specific data you have to enter Whether quantity changes in the material master record are updated Whether value changes to financial accounting stock accounts are updated

Additionally, the material type determines the procurement type of a material, for example, whether the material is produced in-house, procured externally, or both. Moreover, the material type determines which accounts are posted to when a material enters or leaves the warehouse.

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Figure 23: Industry Sector

The industry sector determines which data fields and screens are available for input during material master maintenance. Industry sector is one of several influencing factors. In the configuration of the material master, industry sector can act as one key in specifying whether a field is required, changeable, display only, or hidden. In addition, industry sector is used in configuration to determine what views and what sequence a user can display the material master. Note: From within any of the Create, Change, or Display transactions, users can access the Defaults → Industry Sector menu. This transaction is user-specific, and can control the default industry sector as well as hide the industry sector once a default is set.

Figure 24: Material Numbering

Each material has a unique material identification number. You can assign a number externally or internally. If you assign a number externally, you enter the required character string when you create a material master record. If you assign

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a number internally, you do not enter any material number when you create a material master record. Until you save the material master record, the system sets the internal material number in the appropriate field. When you save, the system automatically assigns the next available number. The type of number assignment that is allowed depends on the material type and is defined in Customizing. First, you have to maintain the number range groups. You then assign the material types to the groups. Note: Material numbering is defined at the client level. You can assign an interval to only one group. You can also change the current number of an interval manually.

Figure 25: Storing and Displaying the Material Number

During configuration, your company can decide how to view material masters. The material master field has a maximum of 18 characters. You can configuration a template to provide breaks in the material number, for example, 123-456-789. In addition, if you do not intend to use all 18 characters from the beginning, you can specify whether leading zeros are to be displayed. The data you enter for material number conversion determines the way material numbers are displayed in dialog functions and printouts only. This means that the information is stored in the database unconverted. Caution: The display format for the material number is effective for all clients.

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

Figure 26: Units of Measure

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

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All units of measure in the SAP system that are additional to the base unit of measure are grouped together under the title “alternative units of measure.” The following alternative units of measure are supported: •

• •

•

•

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

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

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Figure 27: Unit of Measure Groups

For materials that have similar weight and dimension characteristics, you can group together several units of measure in a unit of measure group and assign the group to a material. For each unit of measure in the group, you can enter the conversion factor to the base unit of measure. You maintain unit of measure groups in Customizing for the material master (Logistics - General). Caution: The base unit of measure must not be entered in the unit of measure group.

Demonstration: Prerequisite for Creating Material Master Purpose

System Data System: Client: User ID: Password: Set up instructions: 1. Follow Menu Path: Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately (MM01)

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2.

Point out the need for the Material Number, Industry Sector, and Material type.

3.

Enter material number T-F##, Industry Sector Mechanical Engineering, and material Type Finished Product

4.

Press Enter, and select the Basic Data 1 Screen, and select

5.

Point out the Base unit of measure is a “Required ” Field. Enter PC and a description of Pump GR##

6.

Select Additional Data, and select the Units of measure tab.

7.

Enter a conversion for 1 PAL equals 15 PC

8.

Select

Continue

Save

Creating New Materials When a company needs to create a new material master record, they have to match the process to the SAP ERP transactions. Listed below are several options for creating new material masters Create Material Master Record: Transactions • • • •

MM01 - Create (general) immediately MM11 - Create (general) planned for the future MM#1 - Create with special material type immediately (# = R, B, F, I, H, U, N, V, L, S, K, P, W and G) CEWB - Engineering workbench Hint: The engineering workbench (EWB) enables material master records to be created for new BOM items. The material is usually created immediately. It is generally the case that BOM maintenance cannot work with material master records that are only planned. Note: As soon as a material master record is created with MRP data and a valid MRP type, this material is then automatically included in the planning file, which is extremely important for MRP. When loading the data from a legacy system, the transaction does not create planning file entries.

You can define defaults for certain views, organizational levels, and industry sectors. You can take the dialog boxes for selecting views and organizational levels out of the standard screen sequence. You can hide the industry sector.

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Figure 28: Creating Materials with Default Values

If you copy from another material, values from the material master are copied to the new material master record that you are creating, where you can overwrite them. Hint: As of SAP R/3 4.6X, you can select the Create Views Selected checkbox to automatically create all views that exist in the reference material (departments). Previously, each view (department) had to be viewed individually. This is no longer necessary. Material Master Record Defaults To access material master data efficiently, you can: • • •

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

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

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

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

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

Demonstration: Setting Up Defaults Purpose Setup Defaults for Creating Material Masters

System Data System: Client: User ID: Password: Set up instructions: 1. Follow Menu Path: Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately (MM01)

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2.

From the system menu select Defaults → Industry Sector

3.

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

4.

From the system menu select Defaults →View

5.

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

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6.

From the system menu select Defaults →Organizational levels

7.

Enter in the following data and select

Continue

Org Levels

Copy To:

Copy From Value

Plant

1000

1000

Sales Org

1000

1000

Distribution Channel

10

10

Demonstration: Creating a Material from Scratch Purpose System Data System: Client: User ID: Password: Set up instructions: 1. Follow Menu Path: Logistics → Production → Master Data → Material Master → Material → Create (General) → Immediately (MM01)

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2.

Point out the need for the Material Number, Industry Sector, and Material type.

3.

Enter material number T-B##, Industry Sector Mechanical Engineering, and material Type Finished Product

4.

Press Enter, and select the Basic Data 1 Screen, and select

5.

Point out the Base unit of measure is a “Required ” Field. Enter PC and a description of Pump GR##

6.

Select Additional Data, and select the Units of measure tab.

7.

Enter a conversion for 1 PAL equals 15 PC

8.

Select

Continue

Save

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Creating a Material Using MRP Profiles and MRP Groups The MRP profile allows users to set default values for MRP data fields and to determine whether the values can be changed during material master maintenance. If a change is made to a default value in an MRP profile and the field cannot be changed using material master maintenance, the system automatically changes the field value in all material masters linked to that specific MRP profile. The forecast profile allows users to set default values for forecast data fields and to determine whether the values can be changed during material master maintenance. If a change is made to a default value in a forecast profile and the field cannot be changed using material master maintenance, the system automatically changes the field value in all material masters linked to that specific forecast profile. In addition to the MRP profile, users creating MRP views can use and assign MRP group to the material in the material master (MRP 1 view). The MRP group is defined in configuration under the MRP section. It is used to apply field values to a large number of materials. Caution: When using MRP groups, be aware that the field values do not appear in the material master. This is different from the MRP profile.

Demonstration: Setting Up MRP Profiles Purpose Use MRP Profiles to set default values

System Data System: Client: User ID: Password: Set up instructions: 1. Follow Menu Path: Logistics → Production → Master Data → Material Master →Profile → MRP Profile → Create (MMD1) 2.

Enter MRP Profile FP## ,and press Enter

3.

Enter a description Finished Product ## profile then set the following Parameters: Field

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Fixed Value

Default Value

MRP Type

X

MRP Controller

XSched

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Field

Fixed Value

Scheduling Marg key for Floats

X

Default Value

Lot Size

X

Planning Time Fence

X

Method for Selecting Alt. 4.

Upon setting all indicators select Data Screen 1

5.

Enter the following Data:

6.

Field

Default Value

MRP Type

PD

MRP Controller

1000/0##

Scheduling Marg key for Floats

1000/001

Planning Time Fence

10

Lot Size

EX

Select Data Screen 2 and enter the following data: Method for Selecting Alt.

7.

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X

Select

2 - By Production Version

Save

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Creating Material Masters Using Request Processes with Interactive Forms This next section is based on new functionality in 5.0. It will require the SAP Netweaver solution and is XML Based. Keep it high level at this time. This requires some technical expertise, so we will not include more than just an overview of the new functionality. Fore more detailed information see the help.sap.com. Use the simulation to show students how the finished product will work. In most organizations, one of the major obstacles is defining and managing a process for creating master data. A huge range of forms are used on a daily basis in all types of business, especially for processing requests and approvals. Using paper forms for such processes is singularly inefficient. Delivery and submission is very time-intensive, and usually requires direct contact with an employee. Under such conditions it is difficult for the managers responsible to follow the progress of a process. As of SAP ERP ECC (2004), a new function called Interactive Forms is available for Product Lifecycle Management (PLM) . This new functionality enables you to complete the processing of products and materials considerably more efficiently, as well as to implement company-specific standards for quality throughout the course of the process.

Figure 29: Creating Master Data with Interactive Forms

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

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

The electronic forms contain data on the person who makes the request and the reason for it. Additional process-specific data is added by experts, for example: important product or material data in the New Product request form, or whether stock data should be considered in the change process in the Product Change request form. The data is presented clearly, tailored to the area of responsibility of the employee, and supplemented with notes explaining the process. You process the forms in standardized processes that are defined in the process template. The temporal and logical sequence of the processing steps is linked to the evaluation of conditions. For example, the data required for a particular step must be complete and correct before the subsequent step can be started. The employees responsible, such as the person who makes the request, experts, and managers, are automatically integrated in the separate process steps. Although the employee processes the form offline, information is available from the SAP system. For example, the employee can use the input help for entering system data, and the entries are checked for validity. The manager is notified that the request form needs approval through the Control Center of the Guided Procedures component in the materials management service directory. This is where the manager either approves the data for entry in the SAP system, or rejects it and initiates a notification to the person who made the request. The design of the forms, as well as the processes, have been modeled with the functions of the Guided Procedures component (Web Application Server (WAS) → Composite Application Framework (CAF) ® → Guided Procedures (CAF-GP)). The following overview includes information about where you can find the documentation for the Guided Procedures (CAF-GP) component. •

Documentation for the application, with information on software requirements: SAP Library at http://help.sap.com/: SAP NetWeaver → Composite Application Framework (CAF)→ Guided Procedures (CAF-GP).

•

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

Simulation: ’New Product Request (from RTK-ERP) View the following simulation to learn more about this lesson: File Name: NewProductRqst_IAF.sim

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Lesson: Creating a Material Master

Exercise 1: Creating Material Masters Exercise Duration: 40 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create defaults to be used with material master functions • Create a material master without any template data • Create a material master using Copy From functionality • Create an MRP Profile and use it to create a material master • Create a material master using a • Create a material master using the PLM Web UI

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

System Data System: Client: User ID: Password: Set up instructions:

8xx PLM114 - ##

Task 1: Navigation All of the exercises in this course are written to use the full SAP Menus except for the ones using the PLM WEB UI and they specifically state to use the User Menu SAP_CA_PLM_DESIGNER. This first task shows students how to navigate between the user and full SAP menus. Currently when you logon to the ECC system you are in a User Menu with shorten menu paths specifically for PLM. Most of the exercises in this class are written with menu paths from the full SAP menu. Navigate between the two menus. 1.

Most of the exercises in this course are written using the full SAP Menu paths. Navigate to the SAP Menu using the button on the tool bar.

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2.

Some specific exercises using the PLM WEB UI are written using the User menu SAP_CA_PLM_DESIGNER. Navigate to this User Menu using the button on the tool bar.

3.

If the exercise does not specifically state which menu to use, you can assume that the solutions are written to use the full SAP Menu but can be done using either menu or just transaction codes. Switch back to the full SAP menus and continue with this first exercise.

Task 2: User Defaults In the role of an engineer, you are tasked with creating large quantities of material masters. To make the process run more efficiently, you will use default values and MRP profiles to expedite the creation of material masters. Set your organizational level, industry sector, and view defaults as instructed below. Once completed, set up an MRP profile to populate many of the required fields in the MRP 1 - 4 views. 1.

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

2.

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

3.

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

4.

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

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Data of MRP profile SF## Field Name

Maintenance Strategy

MRP Type

Fixed value

MRP controller

Default

ABC Indicator

Fixed value

In-house production time

Default

5 days

Scheduling margin key

Default

002

Lot Size (Materials Planning)

Fixed value

Purchasing group

Default

000

Planning time fence

Default

10 days

Component scrap in %

Default

1 %

Indicator: Backflush Fixed value

Default Value PD 0## A = important material

EX = exact

2 = work center decides

Task 3: Creating Material Masters As a design engineer, you will be required to create material masters every day. You will use the defaults created in the previous task to speed up the process. In this section, you will be required to create five material masters. This will include two finished products and three semi-finished products. 1.

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

Data

Material Number

T-F##

Material Type

Finished Product Continued on next page

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Basic Data 1 Material Description

Rotary Pump GR ##

Base Unit of measure

PC - piece

MRP 1 MRP Type

PD

MRP controller

0##

Lot Size

EX - Lot for Lot

MRP 2 In house Production

1

Scheduling margin key

001

MRP 3 Strategy Group

10

Accounting 1

90

Valuation Class

7920 - finished product

Price Control

S-Standard Price

2.

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

3.

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

4.

Research and development has just made another significant improvement to the 102–100 pump casing. The changes are significant enough to require a new material master versus engineering revisions. This new casing will be used in several products as a substitute part. Create the following material Continued on next page

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master record by copying from reference material: A Semi-Finished Product with material number T-Z## (## = group number) in plant 1000, copied from material 102–100 using your default views. Change the description to GR## Alt Casing. In addition, to speed up maintenance, use the MRP profile (SF##) that you created in a previous exercise step. 5.

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

Task 4: Your Engineering Department usually creates the initial views of the material masters and assigns the material number as well as the material type. They use the new PLM WEB UI to do their work. Logon to the Web UI as one of the Engineers and create the Basic Data views of the material master. 1.

2.

As an engineer in the Engineering Department responsible for creating material masters, logon to the Web UI using the following data: Client

800

User

PLM-##

Password

initial

Language

EN (or your choice)

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

Data

Material Number

T-F77##

Industry Sector

Mechanical Engineering

Material Type

Finished Product Continued on next page

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Basic Data 1

Data

Material Description

Centrifugal Pump GR ##

Base Unit of measure

PC - piece

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Solution 1: Creating Material Masters Task 1: Navigation All of the exercises in this course are written to use the full SAP Menus except for the ones using the PLM WEB UI and they specifically state to use the User Menu SAP_CA_PLM_DESIGNER. This first task shows students how to navigate between the user and full SAP menus. Currently when you logon to the ECC system you are in a User Menu with shorten menu paths specifically for PLM. Most of the exercises in this class are written with menu paths from the full SAP menu. Navigate between the two menus. 1.

Most of the exercises in this course are written using the full SAP Menu paths. Navigate to the SAP Menu using the button on the tool bar. a)

2.

Some specific exercises using the PLM WEB UI are written using the User menu SAP_CA_PLM_DESIGNER. Navigate to this User Menu using the button on the tool bar. a)

3.

Click on the second from the left button on the tool bar and the menus will change to the full SAP menu.

Since your logon was already assigned to use this User Menu, click the left most button on the tool bar and the menus will change to the role-based user menu..

If the exercise does not specifically state which menu to use, you can assume that the solutions are written to use the full SAP Menu but can be done using either menu or just transaction codes. Switch back to the full SAP menus and continue with this first exercise. a)

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Task 2: User Defaults In the role of an engineer, you are tasked with creating large quantities of material masters. To make the process run more efficiently, you will use default values and MRP profiles to expedite the creation of material masters. Set your organizational level, industry sector, and view defaults as instructed below. Once completed, set up an MRP profile to populate many of the required fields in the MRP 1 - 4 views. 1.

2.

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

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

b)

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

c)

From the menu, choose Defaults → Industry Sector.

d)

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

e)

Choose Continue

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

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

b)

From the system menu, select Defaults →Organizational levels.

c)

Enter the following data:

d) 3.

.

Org Levels

Copy To:

Copy From:

Plant

1000

1000

Sales Org

1000

1000

Distribution Channel

10

10

Select Org Level profiles only on Request, then choose Continue

.

Your recent position will only have you creating materials for a certain business areas within the company. Therefore, set your user’s default for the material master views for which you are responsible for creating. Set Basic

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Data 1, MRP 1 - 4, Work Scheduling, Accounting 1, and Costing 1, to always be selected and select Create views selected so if you use any materials as templates, you will not have to look at all views to create the material.

4.

a)

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

b)

From the system menu, choose Defaults →View.

c)

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

d)

Choose Continue

.

Create an MRP profile for rapid and secure maintenance of MRP data from the material record. Create an MRP profile, SF##, with the description Semi Finished Group ## for use in creating material masters with the material type Semi-Finished Product. Use the parameters in the following table for this exercise. Note: Solution steps will appear after the table in the Solutions section. Data of MRP profile SF## Field Name

Maintenance Strategy

Default Value

MRP Type

Fixed value

MRP controller

Default

ABC Indicator

Fixed value

In-house production time

Default

5 days

Scheduling margin key

Default

002

Lot Size (Materials Planning)

Fixed value

Purchasing group

Default

PD 0## A = important material

EX = exact 000

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Field Name

Maintenance Strategy

Planning time fence

Default

10 days

Component scrap in %

Default

1 %

Default Value

Indicator: Backflush Fixed value

2 = work center decides

a)

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

b)

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

c)

When complete, select Save

.

Task 3: Creating Material Masters As a design engineer, you will be required to create material masters every day. You will use the defaults created in the previous task to speed up the process. In this section, you will be required to create five material masters. This will include two finished products and three semi-finished products. 1.

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

Data

Material Number

T-F##

Material Type

Finished Product

Basic Data 1 Material Description

Rotary Pump GR ##

Base Unit of measure

PC - piece

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MRP 1 MRP Type

PD

MRP controller

0##

Lot Size

EX - Lot for Lot

MRP 2 In house Production

1

Scheduling margin key

001

MRP 3 Strategy Group

10

Accounting 1

2.

Valuation Class

7920 - finished product

Price Control

S-Standard Price

a)

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

b)

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

c)

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

or answer Yes to the question to

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

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

b)

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

c)

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

d)

Choose Save

.

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

4.

5.

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

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

b)

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

c)

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

d)

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

e)

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

f)

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

g)

Choose Save

.

You have just been notified by purchasing that they have come to an agreement with your rubber supplier. This agreement is to sell back the scrap rubber that is made during the stamping of gaskets for your pumps. Create a Semi-Finished Product with material number T-G## (## = group number) in plant 1000, copied from material 100-120 using your default views.

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Change the description to GR## Scrap Rubber. In addition, this will be a co-production, so set the co-product indicator on the MRP 2 view, and you will have to change the valuation class to 7900 - Semi Finished products. a)

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

b)

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

c)

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

d)

Use the ENTER key to move through the views.

e)

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

f)

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

g)

Choose Save

.

Task 4: Your Engineering Department usually creates the initial views of the material masters and assigns the material number as well as the material type. They use the new PLM WEB UI to do their work. Logon to the Web UI as one of the Engineers and create the Basic Data views of the material master. 1.

As an engineer in the Engineering Department responsible for creating material masters, logon to the Web UI using the following data: Client

800

User

PLM-##

Password

initial

Language

EN (or your choice)

a)

Us the following menu path in the role based menu SAP_CA_PLM_DESIGNER PLMWebUI → Internet NWBC. If you get the web page that this website has a problem with its security certificate, choose the option Continue to this website anyway (not recommended).

b)

Enter the above information from the table and click logon.

c)

When asked to change your password, change it to the same password as your PLM114-## logon so you will only have to remember one password. Continued on next page

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

100

Entry Screen

Data

Material Number

T-F77##

Industry Sector

Mechanical Engineering

Material Type

Finished Product

Basic Data 1

Data

Material Description

Centrifugal Pump GR ##

Base Unit of measure

PC - piece

a)

Click on Create Material in the left panel.

b)

Enter your material number, Industry Sector, and material type and select Start.

c)

Enter the Material description, the Base unit of measure, and choose Save and Close.

d)

Back on the Work Overview screen you can click Log Off in the upper right to return to the ECC system.

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

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Classification of the Material Master Lesson Duration: 30 Minutes

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

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

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

This lesson is a simple introduction to classification. You not expected to teach them classification but simply identify how the functionality can be used to expand the material master without modifying tables or the SAP code.

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

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

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Figure 30: Classification of Master Data

Functions of the classification are: • • •

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

To fulfill these objectives, you need to organize your data efficiently. The SAP classification system is a tool for organizing your data that goes far beyond match codes and systematically-structured number assignment.

Demonstration: Updating the Material Master Purpose

System Data System: Client: User ID: Password: Set up instructions: 1. Change the Material Master for your Product T-F##. Logistics → Production → Master Data → Material → Create → Immediately (MM01)

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2.

Select the classification tab

3.

From the classification Tab select menu path Extras → Change class type. Show users how to change class types

4.

Enter Class type 001 - Material Class, and press Enter.

5.

Enter the following Parameters:

6.

Characteristics

Value

Pump Lift

10 m

Pump Capacity

20 m3

Turning Speed

1000

Material

Cast Iron

Usage

Industry Technology

Select Save.

Setup of Classification SAP ERP classification consists of the following components: • • • • •

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

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Figure 31: Classification Functions

Classification can be used to describe or group objects together that have some likeness, but also differences. An object is a classifiable unit (such as a material, vendor, or work center). A characteristic describes specifications of an object, such as length, width, weight, color. Essentially, they are user-defined fields, which are defined as master data. Each characteristics must have a data type (numeric, characteristic, date, and so on). Companies define the length of the field, a template, and limits or ranges to what values can be used. The same characteristic can be used many different times for different purposes. A class type describes a group of objects that have common or similar specifications. When creating a class, a user must specify a class type. Class types control how the classification can be used for various objects. The following classes can be used in conjunction with the material master: • • • •

001 - Material Class 023 - Batch Management 200 - Material (configurable) 300 - Material (variant configuration) Note: In earlier release of SAP ERP batch class 022 (material/plant/client level) existed. In Release 4.7 it was removed and customers should migrate to class 023 (material/client) material. Class types are customized in the IMG: Cross-Application Components → Classification System → Classes → Maintain Object types and Class Types.

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A class can contain one or more characteristics. Within the class, companies can further restrict the characteristic values. A class will then be attached to the material master to specify the custom fields that were needed. A characteristic value represents the specification of a particular attribute, for example, 10 cm, DIN 931, cast iron. Follow these steps to maintain classes: 1. 2. 3. 4.

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

Figure 32: Characteristic Value Assignment

You can use characteristic values in various ways when using classification to determine a material number. For instance you can: • • •

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

Demonstration: Demonstrate Set up of Classification Purpose

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System Data System: Client: User ID: Password: Set up instructions: 1. Display the Class 100. Cross Application Components → Classification System → Master Data → Class (CL02) 2.

Enter Class 100, class type 001 and select

3.

Select the Char. Tab.

4.

Select characteristic C001 and then select Overwrite Values

5.

Select the values tab and enter 50m in the next line available and select SAVE.

6.

Review the definition of the characteristics C001. Cross Application Components → Classification System → Master Data → Characteristics (CT04)

7.

Enter Characteristic C001, and select

8.

Review the parameters and the values.

Display

Display.

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

Figure 33: Finding a Material

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

Demonstration: Purpose

System Data System: Client: User ID: Password: Set up instructions: 1. Search for All Pumps that have a lift of 10 m, a height of 20 m3 and a turning speed of 1000 RPM. Cross Application Components → Classification System → Find → Find Objects in Class (CL30N) 2.

Enter Class 100 and class type 001

3.

Enter the following characteristics values 10 m, a height of 20 m3 and a turning speed of 1000 RPM and select Find in Initial Class

Use of Batch Classification Some industry sectors, in particular in the process industries, need to work with the homogeneous subsets of a material or a product, which means, batches along their entire supply chain. Batch management is integrated with all the applications of the SAP ERP and supports the management and processing of the batches and lots in all the business processes of a company. In particular, batch management is used in Supply Chain Management. A batch can be followed through the whole supply chain, from the entry of the raw materials through the production of the finished product, and all the way to the sales and delivery to the customer. To assign a batch to a material at the various points in the supply chain, you create a batch master record. For example, if the subset of a material that is subject to batch management requirement leaves a production process (process order) with certain specifications, it is posted to the stock with a batch number and can then be clearly identified. A batch master record is identified by an alphanumeric batch number. You can select the level at which you want the batch number to be unique in accordance with the structure of your plant, company, and operational requirements.

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

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

Figure 34: Materials and Batches

In SAP ERP, batch master records depend on the corresponding material master records. Batches are created for a material. The batch object contains the key fields: Material, Batch, and Plant. The Plant field is relevant only if the plant level is used as the batch level. Normally, the data of a material master record is valid for all the batches assigned to it. In contrast, a batch master record contains the data that uniquely identifies a batch and characterizes it as a non-reproducible unit. You can further describe batch properties by classifying them in a class of the class type, 023 Batch. If a material is to be produced in batches and is subject to inventory management, you must set the Batch Management indicator in the material master views Purchasing, Work Scheduling, or Warehouse Management. When you define the specifications for the batch master records, the higher-level material master records are assigned to the classes belonging to the class type, Batch. In these classes, all the material and batch properties are stored as characteristics.

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The class type, Batch, specifies a hierarchical relationship between the object types, Material and Batch: When you create a batch for a material, the batch is automatically assigned to the same class of the class type, Batch, that was used to classify the material. This ensures that the same characteristics are used for the material and the batch. In the SAP R/3 Enterprise, this is called characteristic inheritance. You can define the value ranges or the fixed values for a characteristic of a class. These factors specify a maximum value range that applies to all the objects assigned to this class, in this case materials and batches. In the material master record, you can further restrict the values preset by the characteristics. The restrictions are inherited by the batch of the material. You can then only assign values to the characteristics of the batch that lie within the range specified for the material.

Demonstration: Demonstrate Batch classification of the material Master Purpose

System Data System: Client: User ID: Password: Set up instructions: 1. Review the classification data for he finished product, T-RI200 (Corn Syrup) at plant 1100. In addition Check whether the Batch management indicator is set on the General plant data/storage 1 view. 2.

It has been assigned a class type 023, and batch class T-CL200. Characteristic T-CH400 Dextrose Equivalent, and has a value range of 50% - 80%. Note: The characteristic by definition has a range of 30% to 99.99%, however it has been restricted further in the Material Master Record.

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3.

Enter inventory for the T-RI200 at plant 1100, storage location 0001, using transaction MB1C, Movement type 501

4.

Enter 5,000 kg, and assign batch number DEMO-1, with a dextrose and SAVE Equivalent of 75%, Select

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5.

OPTIONAL Logistics → Central Functions → Batch Management → Batch Information Cockpit (BMBC)

6.

Enter material T-RI200, Plant 1100, on the classification tab enter a selection class T-CL200, and select Create Values

7.

Select

8.

Select Maximize Navigation Area

9.

Drill down and review the details of the batch(s). Double click to see the batch master

Execute

10. Select Display selection result for stock to see Inventory management numbers.

Use of Variant Configuration in the Material Master In some industries, it makes sense to allow customers to request a product with many options that suit their exact needs. However, if the number of options is large, and no two products are likely to be exactly the same, companies could end up with more master data than is feasible to manage. A personal computer (PC), for example, may have different hard drive options, processors, or graphics and sound options. This PC, therefore, has a large number of variants. Like the PC scenario, your company may have a situation in which it manufactures or sells products of which some exist in many variations. In order to reduce your workload and storage costs, and to enable you to maintain every possible end product variant, you choose to use the SAP ERP solution for variant configuration.

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Figure 35: Configurable Personal Computer

Many steps are necessary to build up the master data for a configurable material. First, you must use the SAP classification system to describe the product characteristics. You allocate the characteristics to a class used for variant configuration. You then maintain object dependencies for characteristics and characteristic values so that only allowed values can be chosen. These object dependencies are rules which define which components are compatible with others. You must also maintain the necessary settings for the configurable material in the material master. You create a configuration profile by specifying the configuration parameters and allocating the material to the class with the characteristics that describe it. The components and operations for a material are specified in a super BOM and a super task list. You maintain object dependencies for the BOM components and task list operations that can only be selected for particular variants. Before you use variant configuration productively, you should simulate the configuration. This allows you to check whether all the data has been correctly maintained. Products with variants often have dependencies between the individual characteristics in which, not all combinations of characteristics are allowed. In the case of the pump, for example, a rotary pump with manual and electric drive may be available, but a piston pump may only be available with an electric drive. The term configurable product is used to denote a product that can be manufactured in several variants. It comprises all the possible characteristics of the product, and is therefore not representative of any single product.

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In the case of products that exist in many variants, the Super BOM contains all the parts that might be required to manufacture the configurable material. The parts actually required can be determined from the object dependencies. Likewise, the Super Routing contains all the operations that could be needed to manufacture the configurable material. The operations and production tools and resources that are actually needed for manufacture can be determined from the object dependencies. A special product structure is dynamically generated for a configurable material during sales order processing.

Demonstration: Demonstrate variant configuration of the material master Purpose

System Data System: Client: User ID: Password: Set up instructions: 1. Display the material master for product T-VPC99. Select views: Basic Data 2, and Classification. 2.

At the bottom of the Basic Data 2 view, note the configurable material indicator

3.

Display the Classification view, and if necessary Extras → Class type , switch to class type 300 - Variants

4.

Demonstrate the super BOM (CS02) for T-VPC99 at plant 1200 Note: Point out the duplicate item numbers and the object dependency indicators. By double clicking on the object dependency indicator you can see the rules

5.

Demonstrate the Super Routing (CA02) for T-VPC99 at plant 1200. Point out the object dependency indicators in some of the routing steps.

6.

OPTIONAL Create a sales order with the following data:

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7.

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Field

Value

Order Type

OR

Sales Org

1000

Dist. Chnl

10

Division

00

Sold-to

1000

Ship-to

1000

P.O.

Demo1

Material

T-VPC99

Qty

1

When the configurable screen appears, create your computer. Note: The hard disk has object dependencies. Look at the options first, then enter a CPU value of the PC of Standard, then review the hard drive options again.

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Exercise 2: Material Classification Exercise Duration: 15 Minutes

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

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

System Data System: Client: User ID: Password:

8XX PLM114 - ##

CATT: Set up instructions: 1.

Not CATT necessary

Must have created material masters in Lesson “Creating a material Master”

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

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

2.

List the characteristics that belong to class 100 by choosing the Characteristics tab. Continued on next page

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Characteristic

3.

Description

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

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

Update your material master for pumpT-F## by adding the classification view and by assigning it to material class 100 - Pumps. Give it the following data: Note: If you have not already done so, you will have to create the classification view.

2.

Characteristics

Value

Pump Lift

10 m

Pump Capacity

20 m3

Turning Speed

1000

Material

cast iron

Usage

Industry Technology

Search for all materials that have the following characteristic values:

Continued on next page

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Characteristics

Value

Pump Lift

10 m

Pump Capacity

20 m3

Turning Speed

1000

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

2.

3.

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

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

b)

Enter class 100 and class type 001 and choose Display

.

List the characteristics that belong to class 100 by choosing the Characteristics tab. Characteristic

Description

C001

Pump Lift

C002

Pump Capacity

C003

Turning Speed

C004

Material

C005

Usage

What values, if any, have be assigned to C001 - Pump lift? Hint: Select the characteristic and select Display Values Values 10 m 20 m 30 m 40 m Your instructor may have added another characteristic during a class demonstration via the material master. Use the green back arrow to return to the main menu. Continued on next page

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

Update your material master for pumpT-F## by adding the classification view and by assigning it to material class 100 - Pumps. Give it the following data: Note: If you have not already done so, you will have to create the classification view. Characteristics

Value

Pump Lift

10 m

Pump Capacity

20 m3

Turning Speed

1000

Material

cast iron

Usage

Industry Technology

a)

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

b)

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

c)

Enter class 100 and press Enter. Note: If a class type other than 001 appears in your material master, choose Extras → Change class type and enter class type 001.

d)

2.

Enter the data from the above table; make sure to choose after selecting a value and choose Save and use the green back arrow to return to the main menu.

Search for all materials that have the following characteristic values:

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Characteristics

Value

Pump Lift

10 m

Pump Capacity

20 m3

Turning Speed

1000

a)

Choose Cross Application → Classification System → Find → Find Objects in Class (CL30N).

b)

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

c)

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

d)

Make sure your pump appears on the list and use the green back arrow to return to the main menu.

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

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Managing the Material Master Lesson Duration: 45 Minutes

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

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

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

In this lesson, you will teach participants how to manage the lifecycle of a material master after created. This will include, manual changes, mass changes, deletion and archiving a material.

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

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

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

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

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

Figure 36: Extending the Material Master

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

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

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

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Department

Maintenance status

Work scheduling

A

Accounting

B

Classification

C

MRP

D

Purchasing

E

Production resources/tools

F

Costing

G

Basic data

K

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

Demonstration: Extending the Material Master Purpose System Data System: Client: User ID: Password: Set up instructions: 1. Extend material T-F77## by adding the MRP1 -14 view.

124

2.

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

3.

Set the Maintenance status to : D - MRP and enter Material T-F77##

4.

Select

5.

Select your Material T-F77## and select Maintain Materials

6.

In the Pop up window, continue through the error, but enter Plant 1000 and MRP Profile SF01.

7.

From the MRP 1 view Select

Execute

Save

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

Because the material type influences internal processing, the system checks which changes are allowed. You can change the material type without restriction if no stocks, reservations, or purchasing documents exist. If stock, reservations, or purchasing documents exist, the material type can be changed if: – –

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

Demonstration: Changing the Material Type Purpose System Data System: Client: User ID: Password: Set up instructions: 1. Follow menu path Logistics → Production → Master Data → Material Master → Material → Change Material Type (MMAM) 2.

Enter Material P-100, and new material type Semi-finished production, and select execute

3.

Review the report.

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

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

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

Demonstration: Change Material Master MM02 Purpose System Data System: Client: User ID: Password: Set up instructions: 1. Follow menu path Logistics → Production → Master Data → Material Master → Material → Change → Immediately (MM02) 2.

Change the Planning time fence on the T-Z## casing to 10 days and save.

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

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Figure 37: Material Status

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

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

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

Choose Extras → Status information in any screen.

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

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

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

Demonstration: Purpose System Data System: Client: User ID: Password: Set up instructions: 1. Demonstration for material status 5 minutes 1.

2. 3.

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

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

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Figure 38: Mass Maintenance of Material Master

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

Start the transaction for mass maintenance, MM17. If you have already defined a variant, you can enter this here. Select the tables for which you would like to see the data. Select the fields you want to change on the relevant tab page, and click Execute. Enter the desired selection criteria. You can select other fields by clicking Select Fields. The system selects the data records. Depending on how many data records you have selected, the system may ask whether you would like to continue working in the dialog or whether you would like to perform the changes in the background. If you choose the second option, a workflow will inform you later that the changes you made were carried out. If you continue working in the dialog, the system will display the data records you have selected.

5.

6.

Enter the new value in the corresponding column, select the column header (for example, short text) and the data records you wish to change and choose Change Field Values. You have the following options: • Change only those fields that have a definite current value • Display previous value • Test changes Save the data. The system will perform a consistency check for the data you changed. Changes that lead to data discrepancies are not executed and a note is entered in the log.

Demonstration: Demonstrate Updating Material Masters with Mass Maintenance Purpose System Data System: Client: User ID: Password: Set up instructions: 1. Follow menu path Logistics → Production → Master Data → Material Master → Material → Mass Maintenance (MM17)

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2.

Select Plant Data for Material (MARC), and select the Fields tab.

3.

Select

Find, and enter MRP Type

4.

Select

Execute

5.

At the bottom of the screen select

6.

Scroll through the list on the right and find MRP Controller and select Choose

7.

Enter MRP Controller 0## and Plant 1000, and select

8.

In the section marked new values change the MRP type to P1.

9.

Select the MRP type column, and then select several Material Master and select Carry out a Mass Change

10. Select

Choose selection fields

Execute

Save

11. Follow menu path Logistics → Production → Master Data → Material Master → Material → Display → Immediately (MM03) 12. Review the MRP types for one of the materials you updated via mass processing

Archiving the Material Master As a material approaches the end of its life cycle it should be removed from the data base. You can flag materials for deletion by setting the deletion flag in the material master record. Materials to be deleted are determined by the system by using a proposal list. The deletion flag can be scheduled for the future and must then be activated at the relevant point in time.

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Figure 39: Deleting a Material

Deleting a material Explain the steps required to delete a material record: 1. Set deletion flag + 2. Reorganize. Explain that deletion flag can be “with proposal list” or “planned”. Planning must be activated. A material master record can only be deleted if it meets certain criteria (see documentation archiving of materials -> Deletion criteria). Archiving a material A material can be archived before being deleted. Explain the steps required for archiving: generate sequential archiving file 
2. Set deletion flag 
 3. Start deletion program Reorganization runs can also be incorporated for each job. Note: Archived data can be displayed, but not retrieved. All records flagged for deletion are deleted during a reorganization run provided they are no longer being used, for example, as a BOM header.

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

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

Figure 40: Archiving a Material

You can also archive material master records. The data is stored in a sequential file (archive file). Archived data can be deleted from the database using the deletion program or reorganization. Archived material master records can be displayed, but they cannot be retrieved. Using transaction MM71, Archive/Delete, you can see which other objects need to be deleted prior to a material master. By clicking the Network Graphic icon , you can see which objects needed to be deleted prior to deleting and archiving the material master. Archiving and reorganization are handled in greater detail in the administration courses.

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Demonstration: Demonstrate Archiving the Material Master Purpose System Data System: Client: User ID: Password: Set up instructions: 1. Create Material Pump-##, by copying T-F1## at plant 1000, use your defaults, and SAVE 2.

Set the deletion flag for your Pump-## Menu Path Logistics → Production → Master Data → Material Master → Material → Flag for Deletion → Immediately (MM06)

3.

Enter the material and Plant and press Enter

4.

Select the plant indictor and select SAVE

5.

Try to change the MRP 1 view for Pump-## at plant 1000 Note: Note you will get a warning deletion flag is set, but material can still be used.

6.

Archive plant 1000 for your Pump-## Menu Path Logistics → Production → Master Data → Material Master → Other → Archiving→ Material → Archive/Delete (MM71)

7.

Enter Variant PUMP-##, and select Maintain Variant.

8.

Select Maintain for all selection screens

9.

Enter your material PUMP-##, and select the Production Mode radio button, and select Detailed Log

10. Select Attributes, and enter a archive test and SAVE 11. Return to the entry screen and select Start date 12. Select Immediate, and select SAVE 13. Select Spool Parameters and select Continue

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Control Using Material Type Only the most important topics of configuration will be covered here. Additional topics can be found in the appendix.

You specify a material type for each material. The material type is part of the general data of a material. By specifying which views can be used for a material type, you determine which user departments can maintain a material with this material type.

Figure 41: Control Using Material Type

You can control the type of inventory management (quantity and/or value) for a material type depending on the plant. Price control can be defined as a default value or as a fixed value. Material stock accounts and consumption accounts are assigned by using valuation classes. You can determine inconsistencies in valuation areas using the Customizing for the material type. The material type is an influencing factor for the field selection and the customized material master.

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

Set Material Types Show the possible settings for material types in Customizing (OMS2). Here, focus on the following: • • • • •

Field selection, screen sequence, and authorization group Control of the procurement type (internal or external purchase orders allowed) Views for material maintenance Type of inventory management Assignment of account category references

Create a new material type MM## with the required settings and test this by creating a new material: T-A##.

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Demonstration for the Material Type 1. 2.

Show the material type “FERT” and explain the individual setting options and their meaning. Create a new material type MA## with the template “FERT” and set
 the control using a new material type as follows: • • • •

3.

External and internal purchase orders are allowed. No external check against a number range Product costing with quantity structure is allowed Maintenance of the following views is permitted: Work scheduling, classification, MRP, costing, basic data,
 warehouse, plant and storage location stock. • Quantities and values are to be updated in all plants • Material valuation should use the moving average price • Account assignment should be made with account category reference 0009 Show that the same number assignment applies to the new material type as to material type “FERT”. Hint: The new material type is used in the following demonstrations, in that a new field reference and screen sequence is added and tested by creating a material.

Material Status The material status allows you to control the use of a material for business purposes. The material status is defined depending on material, client, and plant. You can limit the usability of a material in different ways: • •

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

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Figure 42: Material Status

You can display whether a material is subject to restrictions, and what these restrictions are with the status information function. You can call this function when you create, display, or change a material master record. Proceed as follows: Choose Extras - Status information from any screen. You can define the material status for all plants (basic data view), or separately for each plant (plant view). Hint: The more restrictive status always wins out (independent of storage location or plant).

Material Status Show the possible settings in Customizing for material status (OMS4): Logistics General → Material master → Settings for central fields. Demonstration for the Material Status Create a new material status ZZ, which does not allow processing of these materials in BOM items. Test these settings by creating a bill of material for the newly created material T-A##. Hint: Course participants should use their group number + 10 as the key for the material status.

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Exercise 3: Managing Material Masters Exercise Duration: 20 Minutes

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

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

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

Your new pump T-F77## has slightly different dimensions from the other pumps you work on. This will cause the alternative units of measure to differ from the other pumps. Change the alternative units of measure so that 4 pumps go into a carton, and 8 cartons per pallet. This was the material master that you created using the PLM WEB UI but you can maintain it using the normal transactions. Technically, this information would be maintained by Engineering using the PLM WEB UI but we will use the normal transaction here.

2.

As the business process owner for the material master life cycle, you are experimenting with the idea of creating the material master in parts. With this concept, engineering would develop the client views (Basic data/Classification) and then the functional departments would be responsible for upkeeping their own views.

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Extend the finished product T-F77## to plant 1000 and create the MRP 1 - 4 views (D) and Work Scheduling view (A), using the Extend Material View(s) transaction. Include the following data: Note: Maintain work scheduling first, save your entries, and then maintain the MRP views. Press Enter through any necessary messages.

3.

Field Name

User Entry

Production Supervisor

0##

Prod. Sched. Profile

000001

MRP Type

PD

MRP Controller

0##

Lot Size

EX

In House Production

2 days

Sched. Margin Key

001

Strategy Group

40

Selection Method

2 - Selection by Production Version

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

Task 2: Deleting Material Masters (if enough time) Your research and development department is creating new materials to replace existing materials every day. To make sure that a material is truly obsolete, you must update the material master to make this so. You will create a new material master to use the material/plant status and the deletion flag to obsolete a material. 1.

Your business creates new replacement parts every day. To minimize risk, your company wants to be more expeditious in obsoleting materials. To test this process, you create a material through which you can simulate the process of obsoleting the material. Create the following material master record by copying from a reference material: Create a finished product with material number T-D## (## = group number) in plant 1000, copied from material T-F1## using your default views. Change the description to GR## Pump Obsolete. Continued on next page

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2.

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

3.

To make sure the deletion flag works, try to perform a goods issue using transaction code MB1C for your material T-D## at plant 1000, storage location 0002 using movement type 501. Caution: Do not save your entries.

4.

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

5.

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

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

Your new pump T-F77## has slightly different dimensions from the other pumps you work on. This will cause the alternative units of measure to differ from the other pumps. Change the alternative units of measure so that 4 pumps go into a carton, and 8 cartons per pallet. This was the material master that you created using the PLM WEB UI but you can maintain it using the normal transactions. Technically, this information would be maintained by Engineering using the PLM WEB UI but we will use the normal transaction here. a)

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

b)

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

c)

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

d)

Add the data mentioned above: 1 carton = 4 pc 1 pallet = 32 pc Note: All units of measure are converted from the base unit of measure.

e) 2.

Save

As the business process owner for the material master life cycle, you are experimenting with the idea of creating the material master in parts. With this concept, engineering would develop the client views (Basic data/Classification) and then the functional departments would be responsible for upkeeping their own views.

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Extend the finished product T-F77## to plant 1000 and create the MRP 1 - 4 views (D) and Work Scheduling view (A), using the Extend Material View(s) transaction. Include the following data: Note: Maintain work scheduling first, save your entries, and then maintain the MRP views. Press Enter through any necessary messages.

3.

Field Name

User Entry

Production Supervisor

0##

Prod. Sched. Profile

000001

MRP Type

PD

MRP Controller

0##

Lot Size

EX

In House Production

2 days

Sched. Margin Key

001

Strategy Group

40

Selection Method

2 - Selection by Production Version

a)

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

b)

In maintenance status field select the multiple selection icon and enter D - MRP and A - Work scheduling, one on each line and click .

c)

In the Material field enter your material T-F77## and choose Execute .

d)

Select the line for A - Work scheduling and choose Maintain Materials.

e)

Press Enter through the error message and enter plant 1000.

f)

Enter the data (first two rows) in the above chart and choose Save when finished.

g)

Repeat these steps to maintain the D - MRP views.

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

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

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

b)

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

c)

In the Fields tab, choose Find , enter Prod, and choose Continue . Continue searching using the Find Next function until the Prodn Superv. line appears.

d)

Select the line containing Prodn Superv.: MARC-FEVOR and choose Execute .

e)

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

f)

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

g)

Choose Carry out Mass Change

h)

Choose Save , and Continue through any warnings. Use the green back arrow repeatedly to return to the main menu.

.

.

Task 2: Deleting Material Masters (if enough time) Your research and development department is creating new materials to replace existing materials every day. To make sure that a material is truly obsolete, you must update the material master to make this so. You will create a new material master to use the material/plant status and the deletion flag to obsolete a material. 1.

Your business creates new replacement parts every day. To minimize risk, your company wants to be more expeditious in obsoleting materials. To test this process, you create a material through which you can simulate the process of obsoleting the material. Create the following material master record by copying from a reference material: Create a finished product with material number T-D## (## = group number) in plant 1000, copied from material T-F1## using your default views. Change the description to GR## Pump Obsolete. a)

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

b)

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

c)

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

d)

Choose Save

. Continued on next page

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2.

3.

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

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

b)

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

c)

Select the above material.

d)

Choose Save

.

.

To make sure the deletion flag works, try to perform a goods issue using transaction code MB1C for your material T-D## at plant 1000, storage location 0002 using movement type 501. Caution: Do not save your entries. a)

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

b)

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

c)

Enter your material T-D## and a quantity of 1 pc, and press Enter. Note: This should result in a warning that the deletion indicator is set.

d) 4.

Do not save your entries.

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

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

b)

Select the Basic Data 1 view.

c)

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

d)

Choose Save

. Continued on next page

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After applying the obsolete material status, try to receive another goods receipt to see if this will prevent possible mishaps with obsolete materials. Use transaction code MB1C for your material T-D## at plant 1000, storage location 0002 using movement type 501. Caution: Do not save your entries. a)

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

b)

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

c)

Enter your material T-D## and a quantity of 1 pc, and press Enter Note: This should result in an error message that states that the material has a status of “Obsolete Materials in plant 1000.”

d)

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Do not save your entries.

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

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Unit Summary

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Unit Summary You should now be able to: • Describe the organizational layout of the material master • List the prerequisites to creating material masters • Use various methods to create material masters • Describe the request process with interactive forms and explain how it might benefit your business • Describe how the material master can use classification to include company-specific fields • Describe how classification can be used for batch management of inventory • Describe how classification can be used for variant configuration • Describe different ways to update or change the material master • Demonstrate the mass maintenance features of the material master • Describe how the material master can be updated using the request processes with interactive forms for materials management • Describe the archiving and deletion process for the material master

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Test Your Knowledge

Test Your Knowledge 1.

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

□ □ 2.

True False

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

□ □ 3.

True False

A batch is a unique homogeneous subset of a material, which is not reproducible. Determine whether this statement is true or false.

□ □ 4.

True False

Variant configuration uses classification to select specific items on the bill of material and the corresponding operation on the routing for products that have many different options. Determine whether this statement is true or false.

□ □

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Answers 1.

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

2.

Only material master records can be classified using the classification system. Answer: False In addition to material master records, the classification system can be used to classify routings, work centers, PRTs, and documents.

3.

A batch is a unique homogeneous subset of a material, which is not reproducible. Answer: True Because each batch has unique characteristic values, it is a unique subset of a material that cannot be reproduced.

4.

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

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Unit 5 Bills of Material

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In this unit you will demonstrate to the participants the different phases of a bill of material’s life cycle. This will include, creation, updates, and deletion. In this unit you will create several bills of material that will be used in the routing lessons.

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

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

Describe the organizational layout of the bill of material Demonstrate the validity process and changing an active bill of material Describe the process of archiving and deleting a bill of material Demonstrate the various bill of material reports that are available to individuals Demonstrate the comparative reporting tools for bills of material

Unit Contents Lesson: Overview of the Bill of Material .....................................152 Exercise 4: BOM Basics...................................................161 Lesson: Managing Bills of Material ...........................................167 Exercise 5: Changing Bills of Material ...................................181 Lesson: BOM Reporting .......................................................195 Exercise 6: Multilevel BOM Reporting ...................................201

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Overview of the Bill of Material Lesson Duration: 45 Minutes

Lesson Overview This lesson introduces the bill of material.

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

Describe the organizational layout of the bill of material

The purpose of this unit is to introduce participants to the BOM. Navigation and definitions are essential here. Specifically the various BOM status(s), BOM header and BOM items. If you use the BOM units without the Material Master units then you must run the CATT ZT_PLM114BOM and ZT_PLM114RTG. This CATT will do the required exercises in the Material Master units and create the material master records which are required to complete the BOM exercises. Please use transaction START_ACADEMYCATTS to execute the CATT needed. THIS CATT IS ONLY REQUIRED IF THE MATERIAL MASTER UNIT IS NOT USED! IT IS NOT NECESSARY TO USE THIS CATT IF THE ENTIRE COURSE IS BEING TAUGHT.

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

BOM Overview and Usage BOMs contain important master data for integrated materials management and shop floor control. In the engineering design department, new products are designed to be suitable for production, as well as for their intended function. The result of this product phase is drawings and a list of all the required parts, the bill of material (BOM).

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Figure 43: Bill of Material Definition

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

Recipe List of ingredients

Figure 44: Terminology

Assembly An assembly is a set of components for a product that belong together for production purposes. The assembly may itself be used as a component in another assembly.

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Single-level BOM A single-level BOM is a set of all the components that represent one or more assemblies. Component, part, and item are all synonyms.

Figure 45: BOM Integration

Data that is saved in BOMs forms a significant basis for various areas within production planning. Engineering design creates BOMs. You can create BOMs in ECC using a computer-aided drawing (CAD) program and a CAD interface. Material requirements planning (MRP) explodes BOMs in order to determine economical order quantities at a particular point in time. • •

In work scheduling, BOMs form the basis for the planning of operations and shop floor control. Production order management uses BOMs to plan the provision of parts.

The BOM is also used: • • •

In the sales order as an aid to entering data In reservation and goods issue as an aid to entering data In product costing to calculate the material usage costs for a product

The simultaneous use of BOM data in several areas of a company shows the great advantage of integrated modules that are linked in such a way that they facilitate a flow of data between various work areas and allow all the users to access the current values at any time.

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Figure 46: BOM Categories

BOM categories define the connection to an object. Material BOMs are used in SCM to represent the structure of products that are manufactured. Order BOMs are used to produce a product for a specific sales order. A document structure can consist of several documents, for example, a program, technical drawings, paper documents, and photographs. You need document info records for these. Equipment BOMs are used in plant maintenance to describe the structure of a piece of equipment and to assign spare parts to the piece of equipment for maintenance purposes. Functional location BOMs are used in plant maintenance to link equipment to specific locations.

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Figure 47: BOM Usage

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

The engineering BOM combines all components of the product from the engineering point of view and contains all technical data. The production BOM is set up from the manufacturing points of view. For example, process data is required for assembly.

The costing BOM is the basis for the automatic calculation of the material usage costs of a product. Of course, you can also work with just one BOM for all areas by using the item status to cover all possible differences. When creating BOMs with different usages for one material, the system saves each BOM with a separate internal number for each usage.

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Figure 48: BOM Status

The BOM status controls BOM processing in different application areas. When you configure your system in Customizing under Bill of Material → Define BOM status, you define the statuses for different indicators that allow or disallow BOM processing. Examples: BOM A A BOM with status 1 can be exploded in MRP and released for a planned order. BOM B A BOM with status 2 cannot be exploded in MRP or released for a planned order. When you configure your system in Customizing under Bill of Material, each company defines which item statuses are allowed or disallowed for each BOM where-used list. You can define item status fields as required, optional, or disallowed for a specific application area in your company.

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

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

Bill of Material: Structure

Figure 49: BOM Structure

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

158

You enter and maintain data that applies to the entire BOM in the BOM header. You enter and maintain data that applies to an individual component in an item. Items can be divided into subitems if partial quantities have different installation points. Subitems have no control functions.

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Figure 50: Units of Measure

Hint: The system proposes the base unit of measure from the material master record as a default unit. However, if the alternative unit of measure unit of issue is maintained in the Work Scheduling view, this can be used. This uses the conversion factor between base unit of measure and unit of issue, however, which must be entered when you maintain units of issue.

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

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

Figure 51: Low-Level Coding

When you create a BOM, a low-level code is automatically assigned to each material which is used in MRP and costing. You can display the administrative data in the material master record. Low-level codes are used in material requirements planning (MRP) to determine the sequence in which materials are planned and by product costing to determine how costs are rolled up. Low-level coding takes account of the fact that a material may be used in multiple products and on multiple production levels of one product. The low-level code is the lowest explosion level on which a material occurs in all product structures. Low-level coding collects the total requirements for a material on the lowest explosion level where it is used.

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Lesson: Overview of the Bill of Material

Exercise 4: BOM Basics Exercise Duration: 20 Minutes

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

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

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

Go to the bill of material menu.

2.

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

3.

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

4.

What is the component number of item 0010?

5.

What are the component quantity and unit of measure?

6.

Is this component a stock item?

7.

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

8.

Does a BOM exist for this component?

9.

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

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

Continued on next page

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Task 2: The Engineering Department will be responsible to create the initial Engineering BOM. That BOM will then become the basis for the production BOM. Your Engineering Department uses the PLM Web UI to do their work. Logon to the PLM Web UI and create an Engineering BOM for your material. 1.

162

As an engineer in the Engineering Department responsible for creating BOMs, logon to the Web UI using the following data: Client

800

User

PLM-##

Password

(the password you changed it to in Exercise 1)

Language

EN (or your choice)

2.

First, setup the PLM WEB UI for use in your Engineering Department by creating an Access Control Context called GROUP##. Assign it to the PLM_ROOT_CONTEXT as the Parent Context.

3.

Using the PLM Web UI, create an Engineering BOM for T-F## with no plant designation and the following components. Item no.

Item cat.

Component

Quantity

Sort string

10

L

100-100

1

A5

20

L

100-200

2

A1

30

L

100-300

1

A3

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Solution 4: BOM Basics Task 1: Navigate the bill of material for pump T-F1## to become familiar with the SAP ECC structure. 1.

Go to the bill of material menu. a)

2.

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

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

The bill of material categories are: Material BOM Document BOM Equipment BOM Functional location BOM Order BOM WBS BOM

3.

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

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

Value

Material

T-F1##

Plant

1000

BOM Usage

1

Enter data from the above table and choose 4.

What is the component number of item 0010? a)

5.

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

6.

T-B1##

1 PC

Is this component a stock item? a)

Yes (item category = L) Continued on next page

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

8.

Does a BOM exist for this component? a)

9.

Yes (effective until 31.12.9999)

Yes (assembly indicator is set)

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

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

10. What is the valid-to date of this bill of material? then Adm. Data tab.

a)

Select header

b)

The valid-to date is 31.12.9999.

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

Select the Quants/Long txt tab.

b)

1 Pc

Task 2: The Engineering Department will be responsible to create the initial Engineering BOM. That BOM will then become the basis for the production BOM. Your Engineering Department uses the PLM Web UI to do their work. Logon to the PLM Web UI and create an Engineering BOM for your material. 1.

As an engineer in the Engineering Department responsible for creating BOMs, logon to the Web UI using the following data: Client

800

User

PLM-##

Password

(the password you changed it to in Exercise 1)

Language

EN (or your choice)

a)

Use the following menu path in the role based menu SAP_CA_PLM_DESIGNER PLMWebUI → Internet NWBC.

b)

Enter the above information from the table and click logon.

Continued on next page

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2.

3.

2010

First, setup the PLM WEB UI for use in your Engineering Department by creating an Access Control Context called GROUP##. Assign it to the PLM_ROOT_CONTEXT as the Parent Context. a)

In the left panel, scroll down and choose Create Access Control Context.

b)

Enter GROUP## as the new Context name and accept the default Context Type Standard context.

c)

Enter PLM_ROOT_CONTEXT as the parent context and click Start.

d)

Enter the description GR## Context, click Activate context, Save, and Close to return to the Work Overview screen.

Using the PLM Web UI, create an Engineering BOM for T-F## with no plant designation and the following components. Item no.

Item cat.

Component

Quantity

Sort string

10

L

100-100

1

A5

20

L

100-200

2

A1

30

L

100-300

1

A3

a)

From the Work Overview screen click Create material BOM in the left panel.

b)

Enter material number T-F##, BOM Usage Engineering/design, and choose Start.

c)

Enter the component data in the above table and click Save.

d)

Click Additional Functions → Add to favorites and click Close to return to the Work Overview screen.

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

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Lesson: 133

Lesson: Managing Bills of Material

Managing Bills of Material Lesson Duration: 45 Minutes

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

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

Demonstrate the validity process and changing an active bill of material Describe the process of archiving and deleting a bill of material

Managing BOMs unit introduces BOM validity, Group BOM and the various item status. Discuss the group BOM and items thoroughly. There is also some slides introducing engineering change management. This should be discussed at a high level. Avoid detailed ECM discussions as they should be covered in PLM150.

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

Validity of the Bill of Material To define the precise conditions under which a bill of material must be used by different areas in a company, you define an area of validity and a validity period.

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Figure 52: Validity: Area (1)

The area of validity defines which plants can use a bill of material. You can extend the area of validity by assigning the same bill of material (with the same internal BOM number) to a material in different plants. If you do this, note that still only one BOM exists, so any changes you may make will affect all plants. There must be a plant view for the BOM header and all the item materials in each plant that the BOM is assigned to.

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Figure 53: Validity: Area (2)

Material BOMs can be effective on different organizational levels. A material BOM can manage data that is directly relevant to production. In this case, the area of validity is the plant. The plant is a place of work where all the necessary work scheduling activities are organized, for example: • •

Planning of material requirements Creation of routings

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

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Figure 54: Validity: Area (3)

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

Figure 55: Validity: Period

The validity period is the time during which the BOM is valid. This period is defined by the following entries in the BOM header and in the BOM item: Valid-from date When creating a BOM, this date specifies the point in time from which the BOM header or BOM item is effective. If you create or change a BOM by entering a change number, the system copies the valid-from date from the change master record.

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Valid-to date This date marks the end of the validity period for the BOM item. The system calculates this dynamically. Hint: The system assigns a default valid-to date of December 31, 9999. If you change a bill of material with a change number that has a valid-from date, the validity period of the previous state of the object ends at 0.00 hours on that date. You can define a valid-from date for an entire BOM and for individual items.

BOM Structure and Sub-Items

Figure 56: BOM Structure

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

2010

You enter and maintain data that applies to the entire BOM in the BOM header. You enter and maintain data that applies to an individual component in an item. Items can be divided into subitems if partial quantities have different installation points. Subitems have no control functions.

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Figure 57: Subitems

Subitems represent different installation points for partial quantities of an item. For every subitem, you can also maintain a short text next to the subitem quantity. The sum of the subitem quantities replaces the item quantity. A subitem has no control functions in the BOM. This means, for example: • •

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

BOM Management - Item Details Each BOM item must have anitem category assigned to it. The item category defines the features and functions of an item. The item category identifies whether special data must be processed, and controls further system activities.

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Figure 58: Item Categories

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

Is it necessary to enter a material? Does the item support quantity-based inventory management? Are both plus and minus signs supported? Are subitems supported? Which screens are selected and how does the screen layout of the item detail screens look?

Note that you cannot change the item category after you have entered the item. You can only correct an entry for the item category by deleting the item and then creating a new one.

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Figure 59: Non-Stock Items / Item Category: N

You can create non-stock items both with and without a material master record. If you create a non-stock item without entering a material number, you must enter a descriptive text and purchasing data. Using the price data (purchasing data) entered, the system calculates the release strategy. The material group is necessary for creating a purchase requisition. The component is procured directly for the production order. Purchase requisitions are created automatically.

Figure 60: Variable-Size Item/Item Category R

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

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

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

Figure 61: Document Item/Item Category D

If you want to document the product or a component, choose item category D. Prerequisites for documenting a product or component are as follows: A document info record must exist for the document, and be maintained in document management. The document info record contains basic information for integration into the business process, for example, information about the processing state and the storage location. Depending on the document type, you can manage various types of document data (such as technical drawings, photos, or texts). You can use these documents to describe an object comprehensively. You can display the document on the screen.

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Figure 62: Class Item/Item Category K

A class item has characteristics and is used in a configurable BOM. You can use classes that have materials or documents classified in them (with class types 200, 201, and 300) as class items. When you configure a BOM, the class node can be replaced by a specific material or document.

Figure 63: Recursion

Explain the problem of recursion. Demonstrate recursion by including the header material as an item in a BOM. Note: Responsibility for the termination criteria lies with the user who created the recursive BOM. See also SAP note: 161742

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Demonstration for Recursion 5 minutes In the BOM for assembly T-B00, create an item 40 with the part number of the finished product T-F00. Show that recursion is allowed. Explain that the structure is not exploded endlessly because the system has been programed with termination criteria (max. low-level code) A BOM is recursive if the product contains a component that has the same object number as the product. Recursion may be an error, but in some cases it may be intentional. If the system recognizes the recursion online, you see this message: Error: BOM is recursive In exceptional cases, recursion can be recognized only by the update program. The person who creates the recursive BOM receives a message. If you want to create a recursive BOM, set the Recursiveness allowed indicator in the BOM item.

Figure 64: Item Control Indicators

Show the item control indicators on the appropriate views and give a brief explanation of these.

The various item categories can be combined with various indicators. Thus special procedures can be controlled. Screens: B = Basic data

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S = Status/lng text You can set most control indicators in the material master. Most are not copied to the BOM. You can make settings for MRP data on the Basic Data screen for the BOM item that override the indicators in the material master record. Do not explode phantom assembly. Individual requirements indicator Direct production (special procurement key SOBSL 52) Long-term planning

Deleting the Bill of Material Bills of material can be deleted in several ways. Deleting a Bill of Material Explain only.

•

You can delete bills of material using: – –

The deletion function Deletion flags

•

You can:

•

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

•

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

Using the delete function, the BOM is removed from the system immediately. If engineering change management is used, the BOM is deleted on the valid-from date of the change master record. If you set the deletion indicator in the BOM header, the BOM is deleted during the next reorganization run. Deletion at header level removes the entire BOM, whereas deletion at item level removes only the specified item.

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If you delete a BOM without history (without a change master record) the deletion is carried out immediately. Once the deletion has been executed, you can create a new BOM for the same material, plant, and where-used list. If you delete a BOM with history (and so with a change master record) the system deletes the bill of material on the valid-from date of the change master record. Before deleting a BOM, the system checks for: • •

Items with object dependencies to check whether the change master supports maintenance of dependencies for configurable BOMs. Items with operation assignments. If assignments exist, the system displays the relevant message.

See the SAP Library for more information. You can find out more about SAP document management in the PLM120 course.

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Exercise 5: Changing Bills of Material Exercise Duration: 40 Minutes

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

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

Task 1: Using the BOM with Usage Engineering/design which was created by the Engineering Department create a group bill of material with Usage Production that can be assigned to plants or used as a template to create plant BOMs. What is the internal BOM number?____________ 1.

2.

Before you create a production BOM, display the Engineering BOM that was created by your Engineering Department for material T-F##. Field

User Entry

Material

T-F##

Plant

leave blank

Usage

2 (Engineering/design)

Alternative

No entry

Valid from

Today’s date

Using the Engineering BOM for T-F## created by the Engineering Department create a group BOM with usage Production Note the following when you create a group BOM:

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Field

User Entry

Material

T-F##

Plant

group BOM has no entry for plant

Usage

1 (Production)

Alternative

No entry

Valid from

Today’s date

3.

Which system message do you get, and why?

4.

Enter the copy from material number T-F##, leave plant blank, enter Usage 2 Engineering/design, and click

, Continue.

Save the BOM and display the header using the transaction Change material BOM. Go to the BOM header and make a note of the internal BOM number: _______________

Task 2: Create and change plant validity. 1.

Assign the group BOM to plants 1000 and 1100.

2.

Why can you not assign it to plant 1100?

3.

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

4.

Delete the plant assignment (plant 1000).

5.

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

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

Change BOM T-F## in plant 1000.

2.

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

3.

Add component 100-600. Item no.

Item cat.

Component

Quantity

40

L

100-600

2

The two support bases are mounted on the pump. The two support bases should be assembled at the front and the back of the pump. Create subitems for this. 4.

5.

Add a non-stock item by entering the data below. Item no.

Item cat.

50

N

Component

Quantity 1

Item text

One non-stock item

Purchasing org.

1000

Price

10 EUR

Purchasing group

000

Cost element

415000

Material group

Metal processing

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

Item cat.

Component

Quantity

60

R

100-700

1 piece

Size 1

200 mm

Size 2

300 mm Continued on next page

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Note the calculated variable-size item quantity. Change variable size from 300 to 400mm. Get the system to recalculate the variable-size item quantity. 6.

7.

8.

Add bulk material component 100-130. Item no.

Item cat.

Component

Quantity

70

L

100-130

10

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

Document

Type

DPt

Vs

Quantity

80

T-F1##

DRW

000

00

1

D

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

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Solution 5: Changing Bills of Material Task 1: Using the BOM with Usage Engineering/design which was created by the Engineering Department create a group bill of material with Usage Production that can be assigned to plants or used as a template to create plant BOMs. What is the internal BOM number?____________ 1.

2.

Before you create a production BOM, display the Engineering BOM that was created by your Engineering Department for material T-F##. Field

User Entry

Material

T-F##

Plant

leave blank

Usage

2 (Engineering/design)

Alternative

No entry

Valid from

Today’s date

a)

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

b)

Choose Enter

c)

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

.

Using the Engineering BOM for T-F## created by the Engineering Department create a group BOM with usage Production Note the following when you create a group BOM: Field

User Entry

Material

T-F##

Plant

group BOM has no entry for plant

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3.

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Field

User Entry

Usage

1 (Production)

Alternative

No entry

Valid from

Today’s date

a)

Choose Logistics → Production → Master data → Bills of material → Bill of material → Material BOM → Create or transaction code CS01.

b)

Enter the data from the table above.

c)

Choose the Copy from... icon the warning.

from the tool bar and enter through

Which system message do you get, and why? a)

W: Group BOM The warning message regarding group BOMs can be deactivated from SAP R/3 4.7 onwards.

b) 4.

Choose Enter to work through the warning and continue. Ensure no error messages appear.

Enter the copy from material number T-F##, leave plant blank, enter Usage 2 Engineering/design, and click

, Continue.

Save the BOM and display the header using the transaction Change material BOM. Go to the BOM header and make a note of the internal BOM number: _______________ a)

Enter the copy from material number T-F##, leave plant blank, enter Usage 2 Engineering/design, and click

, Continue.

b)

Select all the components in the Engineering/design BOM for T-F## and click copy again:

c)

Save your BOM by choosing

d)

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

e)

.

twice to access your BOM in change mode.

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

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Task 2: Create and change plant validity. 1.

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

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Plant assignment → Create or use transaction code CS07.

b)

Enter the material number and BOM usage = 1. Do not enter the plant in the top portion of the screen. Enter the plant 1000 in the Assign to section and press Enter

c) 2.

.

Select the checkbox next to the plant and choose Save.

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

3.

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

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

b)

.

The internal BOM number in plant 1000 is the same as the number you recorded earlier for the group BOM of usage production. A reference has been created. The BOM structure is saved under one number in the system.

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Delete the plant assignment (plant 1000). a)

Change the plant assignment: Logistics → Production → Master data → Bills of material → Bill of material → Material BOM → Plant assignment → Change or use transaction code CS08.

b)

Enter the data from the table below. Field

Value

Material

T-F##

Plant



Usage

1

Choose Enter. c)

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

d) 5.

Go back to the Current Assignments and choose Save

.

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

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Sort the BOM according to the sort string. a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create or use transaction code CS01. Enter the data from the table below. Field

Value

Material

T-F##

Plant

1000

Usage

1

Valid from

Today’s date

Select the copy from icon

or press F7.

In the Copy From.. dialog box, enter the material T-F## and BOM Usage 1 and choose Enter

.

Hint: Do not enter the plant in the copy from box. Select all of the components to copy and press the Copy b)

icon again.

Make the following changes: Change the quantity of item 20 from 2 to 1. Maintain item 20 with spare part indicator “A”. Double-click in the item number to access the item details. Select the Status/Lng Text tab. Enter A in the spare part indicator field.

c)

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

d)

Save the BOM by choosing Save

.

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

Change BOM T-F## in plant 1000. a)

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change or use transaction code CS01.

b)

Enter the data from the table below.

c) 2.

Field

Value

Material

T-F##

Plant

1000

BOM Usage

1

Choose Enter

.

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

3.

a)

Double click on the material number 100-200 in the component table for Item 20.

b)

This takes you to the material master for that component.

c)

You can see that the material group is 001 (Metal processing) on the Basic Data 1 tab.

d)

Click the green back arrow to return to the BOM.

Add component 100-600. Item no.

Item cat.

Component

Quantity

40

L

100-600

2

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

Continued on next page

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Create subitems for this. a) Item no.

Item cat.

Component

Quantity

40

L

100-600

2

Select item 40 and choose the Sub-items button. SubI

Installation p 
 oint

Sub-item qty Sub-item text

0001

Front of pump

2

0002

Back of pump

1

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

or press F3.

Note: Quantity is 3 and grayed out. 4.

Add a non-stock item by entering the data below. Item no.

Item cat.

50

N

Component

Quantity 1

Item text

One non-stock item

Purchasing org.

1000

Price

10 EUR

Continued on next page

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Item text

One non-stock item

Purchasing group

000

Cost element

415000

Material group

Metal processing

a)

Enter the item data from the table above. Choose Enter

b)

.

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

c)

A detailed purchasing screen in now displayed. Enter item text data as specified in the table above. Press Enter

5.

.

.

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

Item cat.

Component

Quantity

60

R

100-700

1 piece

Size 1

200 mm

Size 2

300 mm

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

Enter the material data from the table above in the General Item Overview and press Enter. The screen variable-size item data is displayed. Enter the sizes from the table above: Choose Enter. The Qty Var-sz Item is calculated to 0.06 M2.

b)

Change Size 2from 300 to 400 mm and press ENTER. Note the message and that the variable quantity has not been recalculated. To recalculate the variable quantity, delete the existing value (0.06) and press ENTER. The variable quantity is recalculated to 0.08 M2.

6.

Add bulk material component 100-130. Continued on next page

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7.

Item no.

Item cat.

Component

Quantity

70

L

100-130

10

a)

Enter the data from the table above:

b)

Select item and choose Item

c)

Select the Status/lng text tab page.

d)

Select the Bulk material indicator (bottom right)
.

e)

Remove the CostingRelevancy indicator.

f)

Arrow back or press F3.

or double-click on Item. 70.

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

Document

Type

DPt

Vs

Quantity

80

T-F1##

DRW

000

00

1

a)

D

Select the Document tab page. Enter data below:

b) 8.

Choose Save

.

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

Display material BOM by choosing Logistics → Production → Master Data → Bills of Material → Bill of material → Material BOM → Display or use transaction code CS03. Field

Value

Material

T-F##

Required quantity

15

(bottom line)

From the Header, choose the Administrative data tab page.

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Lesson Summary You should now be able to: • Demonstrate the validity process and changing an active bill of material • Describe the process of archiving and deleting a bill of material

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Lesson: BOM Reporting

BOM Reporting Lesson Duration: 20 Minutes

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

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

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

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

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

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

Figure 65: BOM Explosion

This question arises in various situations, such as when: • • • •

You need to determine the requirements for a product. The engineering design department needs to look at the overall structure of a product. You need an overview of all the necessary parts and materials. You need to calculate costs or effects of cost changes.

The BOM application defines the following criteria for the search procedure: • • • •

Priority of BOM where-used list Priority of a specific alternative for a particular multiple BOM Production versions in the material master Checks for particular status indicators

In your user master record, you can enter a default value for the BOM application field. This value is the SET- / GET-parameter CSA.

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Figure 66: Where-Used Lists

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

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

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

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Figure 67: Single-Level and Multilevel Material Where-Used Lists

The where-used list provides an answer to this question: Where is a material used and in what quantity? This question arises especially where there are a lot of multiple-use parts and materials. Examples of situations where this information is required: • • • •

To calculate the requirements for a particular material To find the products that are affected by a change to an individual part To find the assemblies that will be produced late because, for example, delivery of a raw material is delayed To calculate the cost effects on a product if raw materials costs change

Comparing Bills of Material The BOM comparison is useful if: • • •

198

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

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Figure 68: BOM Comparison

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

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Lesson: BOM Reporting

Exercise 6: Multilevel BOM Reporting Exercise Duration: 15 Minutes

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

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

Task 1: Execute and navigate various BOM reports. 1.

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

2.

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

3.

Which items are non-stock items?

4.

Which item is handled as bulk material?

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5.

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

6.

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

Task 2: BOM Comparison. 1.

202

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

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Lesson: BOM Reporting

Solution 6: Multilevel BOM Reporting Task 1: Execute and navigate various BOM reports. 1.

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

Choose Logistics → Production → Master Data → Bills of Material → Reporting → BOM Explosion → Material BOM → BOM Level by Level or use transaction code CS11.

b)

Enter the Material: T-F##(Default) Plant: 1000 (Default) Application: PP01 (Production – general)

c) 2.

Access the report via Execute

or press F8.

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

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

Select Edit → View (F5). . Enter A (Spare part customer A) in the Spare Part ID. field. (To see ALL spare parts, enter X in the Spare part sel. field.) Choose Execute . Fly wheel: 100-200 3.

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

.

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4.

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

5.

How many hexagon head screws M10 (100-130) are required for 10 pumps (T-F##) ? Which report are you using for this? Answer: Choose Logistics → Production → Master Data → Bills of Material → Reporting → BOM Explosion → Material BOM → Summarized BOM or use transaction CS13. Enter the following: Material: T-F## Plant: 1000 Application: PP01 Required quantity: 10 Choose Execute . The answer may vary: approximately 180, including totals indicator.

6.

In which materials and in what quantities is the hexagon head screw 100-130 used? Answer: Choose Logistics → Production → Master Data → Bills of Material → Reporting → Where-Used List → Material or use transaction code CS15. Enter the following: Material: 100-130 Type of where-used list: Direct Select next screen . Enter Required qty: 1 and Plant: 1000. Choose Execute.

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Task 2: BOM Comparison. 1.

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

ChooseLogistics → Production → Master Data → Bills of Material → Reporting → BOM Comparison or use transaction code CS14.

b)

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

c)

Enter the following in the Secondary BOM area: Material: T-F## Plant: 1000 Usage: 1 Change Number:

d)

Choose Summarized Comparison icon.

e) 1. 2. 3.

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

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

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Unit Summary

Unit Summary You should now be able to: • Describe the organizational layout of the bill of material • Demonstrate the validity process and changing an active bill of material • Describe the process of archiving and deleting a bill of material • Demonstrate the various bill of material reports that are available to individuals • Demonstrate the comparative reporting tools for bills of material

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171

Test Your Knowledge

Test Your Knowledge 1.

A bill of material is a complete, formally structured list of components that make up a product or assembly. Determine whether this statement is true or false.

□ □ 2.

True False

All of the components are stored in a multilevel bill of material for the finished goods. Determine whether this statement is true or false.

□ □ 3.

True False

A material BOM is the only BOM category that can be created in the SAP ECC system. Determine whether this statement is true or false.

□ □ 4.

True False

A material BOM can have many different usages for specific departments within a company. Determine whether this statement is true or false.

□ □ 5.

True False

Each material BOM is material and plant unique and each material plant combination BOM has a separate internal number assigned to it. Determine whether this statement is true or false.

□ □ 6.

True False

At minimum a basic data view of a material master record must exist before you can create a BOM for that material. Determine whether this statement is true or false.

□ □

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7.

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The base unit of measure defaults into the BOM item but can be overridden with the issue unit of measure from the work scheduling view if it is populated. Determine whether this statement is true or false.

□ □ 8.

True False

Each time a BOM is saved the system calculates the low level code which is used for planning. Determine whether this statement is true or false.

□ □ 9.

True False

Which report would you use to determine which BOMs will be affected by a component change? Choose the correct answer(s).

□ □ □ □

A B C D

BOM comparison Level by level BOM explosion Multilevel BOM explosion Material where-used list

10. Which report would you use to see an overview of all the necessary parts and materials? Choose the correct answer(s).

□ □ □ □

A B C D

BOM comparison Level by level BOM explosion Multilevel BOM explosion Material where-used list

11. Which report would you use to see the differences between two BOMs with different change statuses? Choose the correct answer(s).

□ □ □ □

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A B C D

BOM comparison Level by level BOM explosion Multilevel BOM explosion Material where-used list

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Test Your Knowledge

Answers 1.

A bill of material is a complete, formally structured list of components that make up a product or assembly. Answer: True A bill of material is a complete, formally structured list of components that make up a product or assembly.

2.

All of the components are stored in a multilevel bill of material for the finished goods. Answer: False All bills of material are stored as single-level BOMs in the system. So the BOM for the finished goods consists of its direct components, each of which may have its own single-level BOM in the system. This linkage creates a multilevel BOM and can be viewed by using BOM reporting.

3.

A material BOM is the only BOM category that can be created in the SAP ECC system. Answer: False The BOM categories that can be created in the SAP ECC system are material, order, document, equipment, and functional location BOMs.

4.

A material BOM can have many different usages for specific departments within a company. Answer: True A material BOM can have production, engineering, costing, sales, plant maintenance usages

5.

Each material BOM is material and plant unique and each material plant combination BOM has a separate internal number assigned to it. Answer: False Each material BOM is unique for the material, plant, usage combination and each of those combinations had a unique internal group number.

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At minimum a basic data view of a material master record must exist before you can create a BOM for that material. Answer: True At minimum a basic data view of the material master must exist before you can create a BOM for that material. If only the basic data view exists, only a group BOM can be created and cannot be allocated to a plant until a plant specific view exists.

7.

The base unit of measure defaults into the BOM item but can be overridden with the issue unit of measure from the work scheduling view if it is populated. Answer: True The system proposes the base unit of measure from the material master record as the default unit. However, if the alternative unit of measure unit of issue is maintained in the Work Scheduling view, this can be used.

8.

Each time a BOM is saved the system calculates the low level code which is used for planning. Answer: True When you create a BOM a low level code is automatically assigned to each material used in MRP and costing.

9.

Which report would you use to determine which BOMs will be affected by a component change? Answer: D The where-used list provides an answer to the questions, where a material is used and in what quantity. It can be used to find the products that are affected by a change to an individual part.

10. Which report would you use to see an overview of all the necessary parts and materials? Answer: C The BOM explosion answers the questions, what a product consists of. To get an overview of the entire structure of all necessary parts and materials a multilevel BOM explosion report is available.

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11. Which report would you use to see the differences between two BOMs with different change statuses? Answer: A The BOM comparison is useful if two BOMs have different change statuses. The comparison can be either single-level or multilevel.

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Unit 5: Bills of Material

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177

In this unit you will demonstrate to the participants the purpose of a work center in modeling a manufacturing environment. This will include, creation, updates, and deletion. In this unit you will create work centers that will be used in the routing lessons.

Unit Overview This unit introduces the concept of the SAP ERP work center and how it is used in the task list. You will be instructed on the creation, maintenance, and configuration of the work center. You will also execute various transactions to manage the process surrounding its life cycle.

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

Describe the purpose and integration points of the task list (routing) Describe the structure and purpose of the work center Describe the purpose of the standard value key and standard values Describe the purpose of defaults in the work center Create standard texts to describe a process step Describe capacities and demonstrate their maintenance Describe the function of a pooled work center Describe a reference work center Use reference and pooled capacities Describe the how the work center integrates with costing Demonstrate how the work center and the task list interact with the cost center

Unit Contents Lesson: Modeling Manufacturing .............................................217 Lesson: Basic Work Center Data and Defaults .............................224 Demonstration: Creating a Work Center ................................226

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Demonstration: Options for Work Center Maintenance ...............234 Exercise 7: Create a Work Center .......................................237 Lesson: Capacities in the Work Center ......................................245 Exercise 8: Capacities in the Work Center..............................249 Lesson: Integrating Costing with the Work Center .........................257

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Lesson: Modeling Manufacturing

Modeling Manufacturing Lesson Duration: 30 Minutes

Lesson Overview This lesson provides a basic definition and introduction to SAP ERP work centers and task lists (routings).

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

Describe the purpose and integration points of the task list (routing) Describe the structure and purpose of the work center

Lesson should be kept at a high level. Purpose is to describe and define work centers and routings. Forming the basis for beginning to model the manufacturing process.

Business Example As the project lead for implementing manufacturing resources, you must be aware of the structural design of the work center object in SAP ERP. You need to learn how the task list and work center are structured to integrate with several business areas in your company. Your company has requirements to use task list and work centers for costing, engineering, and production.

Introduction to Modeling Manufacturing In manufacturing, everything revolves around master data, which determines the relationships between the materials used in production and the production process. Material masters must exist before a bill of material and its components can be created.

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Figure 69: Data: Modeling Manufacturing

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. Routings are more complex and pull the other pieces of master data together. Routings define the operational steps required to produce the item, along with the time required, work center where the work is done, and other manufacturing control data. 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 production resource tool (PRT) to routing operations. Standard SAP R/3 texts can be created and assigned to PP basic data objects. The SAP R/3 classification system can be used to group PP basic data according to user-defined attributes. For the material you want to produce, you must set the procurement type to in-house production (X,E). You must maintain at least one plant-specific view (MRP and/or work scheduling) in the accounting and costing views for the material.

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Figure 70: Work Center

A work center is a location that defines where production activities take place according to order requirements. In different companies, work centers are also called machine centers or capacity centers. Work centers can be defined as individual or multiple machines, people, tools, and so on. Work centers are used in routings (routings, standard networks, inspection plans, maintenance task lists, and rough-cut planning profiles) and in orders. Work centers can also be used to collect capacity for statistical evaluations.

Figure 71: Work Center Integration

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Work centers are integrated with and support a number of areas, most commonly scheduling, capacity planning, and costing.

Figure 72: Routing

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: • • • •

220

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

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Figure 73: Routing Usage

Routings are critical to a number of functional activities within SAP ERP. These form the basis for: • • •

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Lead time scheduling Product costing Capacity planning

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Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson Summary You should now be able to: • Describe the purpose and integration points of the task list (routing) • Describe the structure and purpose of the work center

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Basic Work Center Data and Defaults Lesson Duration: 30 Minutes

Lesson Overview In this lesson you will learn which data is contained in a work center, what is required, and how the data is used. You will also learn how to create a new work center.

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

Describe the purpose of the standard value key and standard values Describe the purpose of defaults in the work center Create standard texts to describe a process step Describe capacities and demonstrate their maintenance

In this lesson discuss which data is contained in a work center, what is required, and how the data is used. Stress the objectives.

Business Example As the engineer/planner responsible for maintaining work centers, you must be aware of the structural design of the objects in SAP ERP. Work centers will only be created periodically after the initial go live of your implementation. In doing so, you need learn how the basic data and defaults will affect the modeling of your manufacturing process in the task list. You will also have to maintain the capacity and scheduling related data for work centers to integrate them properly.

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

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Figure 74: Work Center

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

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

Figure 75: Work Center Data

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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.

Demonstration: Creating a Work Center Purpose Use work center 2050 to explain the most important fields for maintaining operations. For work center 111 with work center category 0001, create only the basic data screen. Explain the rules for maintenance for the standard values. Save the work center.

System Data System: F34 Client: 8## User ID: PLM111-## Password: init Set up instructions: 1. Show the most important fields for maintaining operations. 2.

Create the basic data screen for work center 111 with work center category 0001.

3.

Explain the rules for maintenance for the standard values.

4.

Save the work center.

Standard Value Key Standard values represent the times to be measured when the work center is used on a task list, for example, machine time, labor time, and setup time.

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Figure 76: Standard Value Key

These times are grouped together using a standard value key. This key determines which standard values are displayed for the work center. The standard value key is entered on the work center Basic data tab. The key can be set to required or optional within the work center.

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

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Figure 77: 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.

Figure 78: Standard Text for Operation Description

Standard texts for operation descriptions can be predefined in SAP R/3. To maintain standard texts, choose Routings → Extras → Standard text.

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A standard text key identifies the standard text. You can specify this key in the work center. When you use the work center in a routing, the standard text is copied or referenced in the operation.

Work Center Capacity A major function of work centers is to support capacity planning and scheduling. In order to plan these functions, the available capacity must be maintained in the work center.

Figure 79: Capacity Categories for a Work Center in SAP ERP

Capacity refers to the ability of a work center to perform a specific task. You distinguish between various capacities in a work center, such as labor or machines, by using the capacity category. To plan capacities in more detail, you can define individual capacities for each capacity, for instance in the capacity category Person 3 employees or in the capacity category machine 5 lathes. Capacities can be entered and changed in work centers, but can also be maintained independently. The system distinguishes between: • • • •

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Work center capacities Pooled capacities Reference capacities Default capacities

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Figure 80: Capacity Header

Each work center can have one or more capacity headers to describe any limit to the work it can perform in regards to time. For capacity headers to function, they must be assigned as time to a work center. The capacity header will contain all the necessary information to identify the available capacity for a constraint. •

Scheduling: Operating times and formulas are entered in the work center, so that the duration of an operation can be calculated.

•

Capacity planning: The available capacity and formulas for calculating capacity requirements are entered in the work center.

Work Center Scheduling Parameters Shift sequences and shift definitions can be used for 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.

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Figure 81: Available Capacity Maintenance Using Central Shift Sequences

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. The scheduling basis and formulas to be used are stored in the scheduling view of the work center. In addition, you also have to define location groups for the calculation of move times between the work centers using a move time matrix.

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Figure 82: Scheduling Data at a Work Center

The move time can be maintained separately. You can maintain a minimum move time and a normal move time in the Interoperation times section of the Operation detail screen. If reduction measures are necessary, the system uses the minimum move time for scheduling. Note: The system uses the move time matrix to determine move times only if you have not entered any move times in the Interoperation times section of the Operation detail screen. As a rule, however, the transport time should be determined by means of the location groups from the sequential work centers and the move time matrix in Customizing. 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.

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Work Center Configuration: Default Work Center Only select topics of work center configuration are covered here. Additional topics may be found in the appendix.

You can create a default work center for each plant and work center category.

Figure 83: Configuring Work Centers: Default Work Center

If you create a work center without a template, and a default work center exists, the default work center is used. All screens are blank if no default work center has been created for the work center category and plant. If you create a 
work center with a
 copy template, the default work center
 is irrelevant. Configuring Work Centers – Default Work Center 1 and 2 Use the slides to explain the most important points: • • •

For each plant and work center optional Only works without a copy template

Demonstration for Creating a Default Work Center As in the exercise: Default work center in plant 1000 for work center category PL99. Basic Data:

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Task list usage

001 = Standard routing only

Standard Value Key

SAP1 = Normal production

Default Values: Control key

A control key starting with PP: PP01 = Scheduling, capacity planning, and costing, print time tickets and confirmation

Units of measure for standard values

Minute

Capacities: Machine

001

Formulas

SAP005 , SAP006 (0=formula-related)

Scheduling: Machine

001

Formulas

SAP001, SAP002

Location group

0001

Wait time

5 h, 1 h

no Costing Test: CR02: Work center TEST99 => No effect
 CR01: New work center of category PL99 => It works (exit without saving)

Demonstration: Options for Work Center Maintenance Purpose Add a work center.

System Data System: Client: User ID: Password: Set up instructions:

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F34 8## PLM111-## init

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1.

Point out that default values have been defined for the use of work center category 0001.

2.

Begin to show the creation of a work center with work center category 0002 and 0003.

3.

Change your work center 111 and select Work center → Check to complete the default values. Note: With this menu function, you can also enter the capacity data for the standard available capacity and the scheduling data using the default values.

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Exercise 7: Create a Work Center Exercise Duration: 15 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create and change a work center

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

Task 1: Create work center CENTER## in plant 1000. The work center is intended for two identical new machines with the work center category 0003. 1.

Create work center CENTER## in plant 1000. Hint: To maintain the individual tab pages (screen sequences), select Next screen.

2.

Enter the following on the Basic data tab page: Field

Entry

Description

Pump assembly ##

Person responsible

0##

Usage

009 (All task list types)

Standard value key

SAP1 (Normal production)

Rules for maintenance

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

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Field

Entry

Performance efficiency rate key

Machine - 090 %

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

Task 2: Answer the following questions about the work center that you have just saved. 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 3: Add data for capacity, scheduling, and costing to the work center CENTER##. To do so, use the change transaction. 1.

Enter the capacity category 001, Setup Formula SAP005, Processing Formula SAP006. On theChange Work Center Capacity: Header screen, adjust the capacity data using the following capacity data:

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Field

Entry

Capacity planner group

0##

Grouping

51

Factory Calendar ID

01

Active Version

1

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 2.

3.

Maintain the Scheduling tab page with the following data: Field

Entry

Scheduling basis: Capacity category

001

Setup formula

SAP001

Processing formula

SAP002

Location group

0002

Standard queue time

2 (H)hours

Maintain the following data on the Costing tab page: Field

Entry

Cost center

4230

Activity type

Setup time -1422 Machine time -1420

Formula keys

Setup - SAP005 Machine - SAP006

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Solution 7: Create a Work Center Task 1: Create work center CENTER## in plant 1000. The work center is intended for two identical new machines with the work center category 0003. 1.

Create work center CENTER## in plant 1000. Hint: To maintain the individual tab pages (screen sequences), select Next screen.

2.

a)

Choose Logistics → Production → Master Data → Work Centers → Work Center → Create or use transaction code CR01.

b)

Enter plant 1000, work center number CENTER##, and work center category 0003.

c)

Choose Enter

.

Enter the following on the Basic data tab page: Field

Entry

Description

Pump assembly ##

Person responsible

0##

Usage

009 (All task list types)

Standard value key

SAP1 (Normal production)

Rules for maintenance

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

Performance efficiency rate key

Machine - 090 %

Continued on next page

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a)

Maintain data from the above table. Confirm entries with Enter. Hint: After the work center number, enter the work center description, Pump assembly ##. Use the input help to enter the person responsible, usage, and standard value key. Caution: Do not save or exit the work center at this time.

3.

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

a)

Select Next screen

b)

Maintain the following data on the Default values tab page:

c)

Field

Entry

Control key

PP01 to 
PP99

Unit of measure for standard values

Minute

Reference indicator

Set for the control key

Save the work center by choosing

.

Task 2: Answer the following questions about the work center that you have just saved. 1.

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

2.

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

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Task 3: Add data for capacity, scheduling, and costing to the work center CENTER##. To do so, use the change transaction. 1.

Enter the capacity category 001, Setup Formula SAP005, Processing Formula SAP006. On theChange Work Center Capacity: Header screen, adjust the capacity data using the following capacity data: Field

Entry

Capacity planner group

0##

Grouping

51

Factory Calendar ID

01

Active Version

1

Base unit of measure

Hour

Start/finish time

08:00 / 17:00

Length of breaks

1 hour

Capacity utilization

80 %

Number of individual capacities 2 machines a)

Choose Logistics → Production → Master Data → Work Centers → Work Center → Changeor use transaction code CR02. Choose Enter

2.

and select the Capacities tab.

b)

Enter Capacity category 001 , Setup Formula SAP005, and Processing Formula SAP006.

c)

To access the capacity header data, double-click the number of the capacity category or choose the Capacity header data button.

d)

Enter data from the above table and choose Enter

e)

Arrow back screen.

.

to the Change work center: Capacity Overview

Maintain the Scheduling tab page with the following data: Field

Entry

Scheduling basis: Capacity category

001

Setup formula

SAP001

Continued on next page

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Field

Entry

Processing formula

SAP002

Location group

0002

Standard queue time

2 (H)hours

a) 3.

Enter data from the above table and confirm with Enter

.

Maintain the following data on the Costing tab page: Field

Entry

Cost center

4230

Activity type

Setup time -1422 Machine time -1420

Formula keys

Setup - SAP005 Machine - SAP006

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a)

Select the Costing tab.

b)

Make the required entries from the table above.

c)

Save your work center by choosing

.

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Lesson Summary You should now be able to: • Describe the purpose of the standard value key and standard values • Describe the purpose of defaults in the work center • Create standard texts to describe a process step • Describe capacities and demonstrate their maintenance

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Lesson: Capacities in the Work Center

Capacities in the Work Center Lesson Duration: 45 Minutes

Lesson Overview In this lesson, we will discuss pooled and reference capacities.

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

Describe the function of a pooled work center Describe a reference work center Use reference and pooled capacities

The work center plays an important role in the scheduling process. Through the default value key, it provides the values needed for the calculation using the formulas in the scheduling data screen of the work center. Because a scheduling basis from capacity data is needed for scheduling, you should use these slides to quickly go through standard available capacity and factory calendars. Available capacities that are different from the standard available capacity are covered in course SCM360 and should only be discussed briefly with the slide Available Capacity Maintenance Using Central Shift Sequences.

Business Example As the production planner, you are responsible for maintaining capacity and scheduling-related data for the modeling of the manufacturing process. There is currently a labor pool that is shared among many work centers. This will be modeled as a pooled capacity. Many work centers also operate the same hours. To make maintaining these working hours more efficient, you want to use a reference capacity.

Pooled Capacities Capacity refers to the ability of a work center to perform a specific task. Capacities are differentiated according to capacity category. They are arranged hierarchically under a work center. Capacity can be specific to a given work center, it can represent a group of people or machines, or it can be used as master data for many work centers.

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Figure 84: Pooled Capacities

In SAP R/3, capacity data can be a stand-alone piece of master data called a capacity header. Each work center can have one or more capacity headers to describe any limit to the work it can perform in regards to time. For capacity headers to function, they must be assigned at some time to a work center. In SAP R/3, capacities are created without reference to a work center when modeling a reference capacity or a pooled capacity. A pooled capacity is used to model manufacturing resources that will be shared by many work centers. For modeling purposes, this only makes sense if the pool of resources is actually a capacity constraint. Example, you have five production lines that each require an operator for the entire duration that machine runs. However, you only have four operators in you resource pool. Therefore, only four machines can run at any one time. In SAP R/3, capacity headers can be modeled independently of work centers to support a shared/pooled resource. In the definition of the work center, the pooled capacity will be referenced by the work center to act as a planning constraint during capacity planning.

Reference Capacities Often times in repetitive, high-speed, manufacturing environments, companies divide similar manufacturing activities into manufacturing areas, or departments. Often times, these departments operate at the same starting and finishing times. To properly schedule any logistics activities, users must create and maintain the necessary capacity data. However, if the data that is used to model certain resources is identical, than methods to ease data maintenance should be used.

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Lesson: Capacities in the Work Center

Figure 85: Reference Capacity

To ensure proper scheduling, each work center in SAP R/3 is typically maintained with its available capacity so that you know when the work center is open and closed for business. By creating reference capacities, users can maintain one set of capacities that applies to several work centers independently by linking the capacity data to each relevant work center. When it is necessary to update the capacity, the planner only needs to maintain the reference resource. The information is relevant for all resources that have been linked by the reference function. The first step in creating a reference resource is to create the capacity header. The capacity header for the reference capacity is no different then a work center capacity header. Unlike the pooled capacity, there is no field to indicate that it has a special function. Once a capacity header has been created, users must reference it to the same capacity category in the work centers. In the details of the capacity header, choose Extras → Reference avail. cap. This must be performed on every work center that will use the capacity header as reference data. Once the work center capacity category has been referenced, it can no longer be maintained. The capacity data can only be maintained by editing the reference capacity header.

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Exercise 8: Capacities in the Work Center Exercise Duration: 15 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create pooled capacities • Create a reference capacity • Assign the pool and reference to a work center

Business Example As a general rule, all assembly areas will work the same hours: 7:30 am to 3:30 PM. To eliminate redundant data maintenance, you want to use a reference capacity to model this. The assembly machines are run by a pool of six people who move from machine to machine to assure things are running smoothly.

Task 1: Create Reference Resource Your assembly lines run from 7:30am to 3:30pm. Each line is available 95% of the time, due to preventive maintenance. Create a reference capacity to model this. 1.

Create a machine capacity, REF - ##, Assembly Lines, that will reflect the master data above, and model you high-speed filling line master data.

Task 2: Pooled Capacity in mySAP SCM You are staffed with six operators to run the assembly lines. Model these as a pooled capacity. 1.

Create a pooled capacity, Pool - ##, that will represent the labor force that is responsible for running the assembly lines in plant 1000, based on the figures above.

Task 3: Create a Work Center Create work center Assy-## in plant 1000. The work center will use the reference capacity REF-## and pooled capacity Pool-##. 1.

Create work center Assy-## in plant 1000.

2.

Enter the following data on the Basic data tab page:

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Field

Entry

Description

Assembly line ##

Person responsible

0##

Usage

009 (All task list types)

Standard value key

SAP1 (Normal production)

Rules for maintenance

Setup time - no checking Machine time - no checking Labor time - no checking

Performance efficiency rate key 3.

On the Default values tab page, choose the control key and minutes as the unit of measure.

4.

Add the reference capacity REF-##. Enter the capacity category 001, Setup Formula SAP005, and Processing Formula SAP006.

5.

Maintain the Scheduling tab page with the following data:

6.

Field

Entry

Scheduling basis: Capacity category

001

Setup formula

SAP001

Processing formula

SAP002

Maintain the following data on the Costing tab page: Field

Entry

Cost center

4230

Activity type

Setup time -1422 Machine time -1420

Formula keys

Setup - SAP005 Machine - SAP006

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Solution 8: Capacities in the Work Center Task 1: Create Reference Resource Your assembly lines run from 7:30am to 3:30pm. Each line is available 95% of the time, due to preventive maintenance. Create a reference capacity to model this. 1.

Create a machine capacity, REF - ##, Assembly Lines, that will reflect the master data above, and model you high-speed filling line master data. a)

Choose Logistics → Production → Master Data → Work Centers → Capacity → Create or use transaction code CR11.

b)

Enter the following data: Field

Entry

Plant

1000

Capacity

REF - ##

Capacity Category

001 - Machine

Select Header data (enter) c)

.

Enter the following data in the capacity header: Field

Entry

Capacity Description

Assembly Lines

Capacity planner grp

2##

Pooled capacity

deselect

Grouping

99 - APO

Factory calendar ID

US

Active version

01 - Normal Capacity

Base unit of meas.

H - Hours

Start

07:30:00

Finish

15:30:00

Length of breaks

00:00:00

Capacity Utilization

95

No. indiv. cap.

1

Relevant to finite scheduling

Select

Can be used by several operations Deselect Continued on next page

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d)

Choose Save

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.

Task 2: Pooled Capacity in mySAP SCM You are staffed with six operators to run the assembly lines. Model these as a pooled capacity. 1.

Create a pooled capacity, Pool - ##, that will represent the labor force that is responsible for running the assembly lines in plant 1000, based on the figures above. a)

Choose Logistics → Production → Master Data → Work Centers → Capacity → Create or use transaction code CR11.

b)

Enter the following data: Field

Entry

Plant

1000

Capacity

Pool - ##

Capacity Category

002 - Labor

Select Header data (enter)

.

Field

Entry

Description

GR ## Operators

Capacity Planner grp

2##

Pooled capacity

Select

Grouping

99 - APO

Factory Calendar ID

US

Active Version

01 - Normal Avail Capacity

Base unit of meas.

H - Hour

Start

07:30:00

Finish

15:30:00

Length of breaks

01:00:00

Capacity Utilization

100

No. of indiv. cap

6

Relevant to finite sched.

Select

Can be used by several operations Select Continued on next page

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c)

Choose Save

.

Task 3: Create a Work Center Create work center Assy-## in plant 1000. The work center will use the reference capacity REF-## and pooled capacity Pool-##. 1.

2.

Create work center Assy-## in plant 1000. a)

Choose Logistics → Production → Master Data → Work Centers → Work Center → Create or use transaction code CR01.

b)

Enter plant 1000, work center number Assy-##, and work center category 0003.

c)

Choose Enter

.

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

Entry

Description

Assembly line ##

Person responsible

0##

Usage

009 (All task list types)

Standard value key

SAP1 (Normal production)

Rules for maintenance

Setup time - no checking Machine time - no checking Labor time - no checking

Performance efficiency rate key a)

Confirm entries with Enter. Hint: After the work center number, enter the work center description Assembly line ##. Use the input help to enter the person responsible, usage, and standard value key. Caution: Do not save or exit the work center at this time.

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3.

4.

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On the Default values tab page, choose the control key and minutes as the unit of measure. a)

Choose Next screen

b)

Maintain the following data on the Default Values tab page:

or choose the Default Values tab.

Field

Entry

Control key

PP01

Unit of measure for standard values

Minute

Add the reference capacity REF-##. Enter the capacity category 001, Setup Formula SAP005, and Processing Formula SAP006. a)

Select the Capacities tab.

b)

Enter Capacity category 001, Setup Formula SAP005, and Processing Formula SAP006.

c)

To access the capacity header data, double-click the number of the capacity category, or choose the Capacity header data button.

d)

Choose: Extras → Reference avail cap. Enter the following: Field

Entry

Plant

1000

Capacity

REF-##

Capacity Category

001

Choose Enter

.

Note: Notice that the fields cannot be changed since they are from the reference capacity. to the Change work center: Capacity Overview screen.

e)

Arrow back

f)

Choose Create capacity

.

Enter the following and confirm with Enter: Field

Entry

Continued on next page

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5.

Entry

Capacity category

002

Pooled capacity

Pool-##

Setup Formula

SAP005

Processing formula

SAP007

Maintain the Scheduling tab page with the following data: Field

Entry

Scheduling basis: Capacity category

001

Setup formula

SAP001

Processing formula

SAP002

a) 6.

Field

Confirm with Enter

.

Maintain the following data on the Costing tab page: Field

Entry

Cost center

4230

Activity type

Setup time -1422 Machine time -1420

Formula keys

Setup - SAP005 Machine - SAP006

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a)

Select the Costing tab.

b)

Make the required entries from the table above.

c)

Save your work center by choosing Save

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Lesson Summary You should now be able to: • Describe the function of a pooled work center • Describe a reference work center • Use reference and pooled capacities

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Lesson: Integrating Costing with the Work Center

Integrating Costing with the Work Center Lesson Duration: 20 Minutes

Lesson Overview In this lesson we will describe the integration between costing and the work center.

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

Describe the how the work center integrates with costing Demonstrate how the work center and the task list interact with the cost center

Business Example As the engineer/planner responsible for maintaining work centers, you must be aware of the integration between the work center, the task list, and the cost center. Work centers will only be created periodically after the initial go live of your implementation. You need learn how the initial setup parameters will be continually integrated with the cost accounting module of SAP ERP.

Cost Center Assignment and Integration 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.

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Figure 86: Production Costing

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

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Facilitated Discussion Discuss the costing integration and calculation of activities.

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson Summary You should now be able to: • Describe the how the work center integrates with costing • Demonstrate how the work center and the task list interact with the cost center

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Unit Summary

Unit Summary You should now be able to: • Describe the purpose and integration points of the task list (routing) • Describe the structure and purpose of the work center • Describe the purpose of the standard value key and standard values • Describe the purpose of defaults in the work center • Create standard texts to describe a process step • Describe capacities and demonstrate their maintenance • Describe the function of a pooled work center • Describe a reference work center • Use reference and pooled capacities • Describe the how the work center integrates with costing • Demonstrate how the work center and the task list interact with the cost center

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Unit Summary

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Unit 7 Task Lists

217

In this unit you will demonstrate to the participants the different phases of a routing’s life cycle. This will include, creation, updates, and deletion. Advanced modeling will be covered in another unit.

Unit Overview This unit introduces the basic concept of the SAP ERP task list (routing). You will be instructed on the creation, maintenance, and configuration of the routing. You will also execute various transactions to manage the process surrounding its life cycle. Several advanced functions will be covered in another lesson.

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

Describe the different types of task lists Describe the integration points of the task list Assign manufactured items to routings Allocate material components to operations Maintain cutting measures of variable-size items Describe the functions of suboperations Retrieve additional fields in operations Demonstrate how to make changes with history Demonstrate how to use where-used lists and mass changes

Unit Contents Lesson: Overview of the Task List ............................................265 Exercise 9: Create a Simple Routing ....................................271 Lesson: Creating a Routing and Material Assignment .....................280 Exercise 10: Material Assignment and Component Allocation .......285 Lesson: Suboperations and User-Defined Fields...........................291

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Exercise 11: Suboperations for Material-Specific Capacity Constraints ..................................................................297 Lesson: Reporting and Mass Changes ......................................302 Exercise 12: Task List Changes with ECM..............................309

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Lesson: 218

Lesson: Overview of the Task List

Overview of the Task List Lesson Duration: 20 Minutes

Lesson Overview In this lesson, you will learn about task lists in SAP ERP. We will discuss the different types of task lists and their integration points with other parts of the SAP ERP system.

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

Describe the different types of task lists Describe the integration points of the task list

If you use the TASK LIST units without the Material Master and BOM units then you must run the CATT ZT_PLM114RTG. This CATT will do the required exercises in the Material Master and BOM units and create the material master records which are required to complete the Task List exercises. Please use transaction START_ACADEMYCATTS to execute the CATT needed. THIS CATT IS ONLY REQUIRED IF THE MATERIAL MASTER AND BOM UNITS ARE NOT USED! IT IS NOT NECESSARY TO USE THIS CATT IF THE ENTIRE COURSE IS BEING DELIVERED.

Business Example As the project lead for implementing task lists, you must be aware of the structural design of the task list object in SAP ERP. In doing so, you need to learn how the task list and work center are structured to integrate with several business areas in your company. Your company has requirements to use task lists and work centers for costing, engineering, and production.

Task Lists Types A task list is a non-order-related process for implementing an activity. Task lists are used throughout the SAP ERP system to define a sequence of activities to produce a specific result. Task lists are used in several application areas, including PP, PP-PI, PS, QM, and PM. The following table shows several different types of task lists that are used in the SAP ERP system.

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Figure 87: Task List Types

Routings describe material-related production and are used in production planning. Reference operation sets are not created for a specific material, but can be used as references within routings or copied into routings. They are usually activities that are common to many routings and can be created with either internal or external numbering. Rate routings describe material-related production using production lines and are used mostly by repetitive manufacturing. Reference rate routings are non-material specific activities that are common to many rate routings and can be used as references within rate routings or copied into them to simplify data entry. Master recipes describe material specific production and are used in production planning for process industries. Rough-cut capacity profiles are used to view resource loads in sales and operations planning without BOM explosion. Networks contain instructions on how to perform tasks in a specific way, in a specific order, and in a specific time period, and are used in project systems. Inspections plans describe the inspection process for a material and are used in quality management.

Structure of a Routing A routing determines the sequence of individual operations that are necessary to produce a product. It describes the sequence of activities, where the work is performed, and how much of the work center’s resources will be consumed. A routing can be created with or without a material number. Routings without material numbers can be used by many materials that all use the same production process, production line, or manufacturing steps. A routing is made up of operations to which work centers are assigned. The details of the operations contain the standard values or times of production at that work center. They also contain information about each work center where the work is to

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be performed. The SAP ERP system stores routings in groups that can be either internally or externally assigned. There can be many routings in a group, each distinguished by a different group counter. Other important assignments in the routing include the materials components from the BOM and any PRTs that are required for production. PRTs are items needed for production that are not consumed like tools and fixtures. More than one BOM can have components allocated to the same routing. Components are assigned to the specific operation where they are needed and consumed in the production process. Inspection characteristics can be assigned to the operations in the routing if a quality inspection is to be performed during an operation. Trigger points can also be assigned to an operation to trigger functions when a certain event occurs. Examples of such events might be a change in status or the release of an operation based on another event happening, such as a confirmation.

Figure 88: Routing Structure

Routing Integration A routing is independent of an order and is used in the creation of an order. The operations and information from the routing is copied into the order during order creation. This includes the planned time for each activity within an operation (standard value), the work center, and the control key. The routing information in the order becomes the basis for lead time scheduling, product costing, and capacity planning.

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Figure 89: Routing Usage

A routing is defined at the plant level. This means that the organizational elements for company code, valuation area, and plant all need to be defined prior to creating a routing. A work center is needed to assign to the operation, so a work center must also exist before the routing can be created. The routing integrates with material master data, BOM components, work centers, as well as product costing, capacity planning, production orders, procurement, and planning.

Figure 90: Routing Integration in SAP ERP

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Profiles with Default Values Only the routing Default Values configuration is covered here. Additional topics can be found in the Lesson Sub-Operations and User-Defined Fields and the appendix. In this step, you define task list profiles. A profile is a collection of default values for task list headers and operations. You can minimize the maintenance of task list data as follows: •

Data from the material master is proposed.

• •

Data from the work center can be referenced or copied Data from the profile is proposed.

Figure 91: Default Values Profiles

You can enter a profile in routing maintenance. The values from this profile are proposed when you create a new routing or routing object, such as a header or an operation. This data can either be saved or overwritten. Use the following procedure: 1. 2. 3. 4.

2010

Determine the default values that can reduce the amount of maintenance work in your company. If necessary, define several profiles. Maintain the default values for routing maintenance. Maintain the default values for quality assurance.

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In this step, you can select fields for the following screens: • • • • •

Task list header screens Sequence screens Operation screens PRT overview PRT details

All of the screens where field selection is possible are combined into individual screen groups. For each screen group, you define the modifiable and influencing fields. For modifiable fields, you use an indicator to determine how the individual fields are displayed on the screen: • • • • •

Field is ready for input (standard setting) Field requires an entry (required entry) Field is display only Field is hidden Field is highlighted

If you determine for the list and detail screens for confirmation within the network that work center is a required entry, you must maintain the work center in all confirmations. For the influencing fields, you determine how the modifiable field is displayed on the screen, depending on a value (for example, work center is a required entry for a certain order type). The field selection settings you define can be transported and will remain unchanged when you upgrade to a new release. If a modifiable field becomes a required entry because of a change to an influencing field, the system does not check whether this field is filled with objects that already exist. You cannot modify required fields that are already hard-coded for the application.

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Exercise 9: Create a Simple Routing Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create a simple routing for a material • Create a group routing that is not material specific

Business Example Your business is implementing SAP ERP and you must model the manufacturing procedure for material manufacturing. You must create a routing for materials production.

System Data System: Client: User ID: Password: CATT: If the material master units and the BOM units have not been done prior to this unit, then the CATT ZT_PLM114RTG will need to be executed to build the master data for this unit. Please use transaction START_ACADEMYCATTS to execute the CATT needed. Set up instructions: 1.

Task 1: Create a simple routing for material production. 1.

Create a routing for the production of material T-B## in plant 1000 that consists of the four steps in the table below. The routing should be creation status, valid from today’s date, for production usage, and for lot sizes from 1 to 100,000 Pc. Use the data in the table below to complete the routing information. Primary Operation Data

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Operation #

Work Center

Control Key

Description

10

T-A##

PP01

Lathe casing according to drawing

20

T-B##

PP01

Drill holes

30

T-C##

PP01

Insert Flat gasket

40

T-C##

PP01

Inspect and deliver to stock

Standard Processing Times Activity

Op 10

Op 20

Op 30

Op 40

Setup

10 Min

3 Min

0 Min

0 Min

Machine

30 Min

10 Min

0 Min

0 Min

Labor

30 Min

10 Min

5 Min

10 Min

2.

What are the task list group number and group counter on the header of your routing?

3.

What is the base quantity and operation unit for operation 10 and how does it relate to the standard values?

Task 2: Display your routing and answer the following questions. 1.

Display your routing.

2.

What are the group number and group counter?

3.

When was the routing created and by whom?

4.

What are the validity dates for the routing?

5.

What are the validity dates of operation 20?

Task 3: Create a non-material-specific group routing to manufacture many different pumps that all have the same manufacturing process. 1.

Create a non-material specific routing for the production of several different pumps in plant 1000 thath all use the same five steps in the table below. The routing should be creation status, valid from today’s date, for production usage, and for lot sizes from 1 to 100 only. Use the data in the table below to complete the routing information. Primary Operation Data Continued on next page

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Operation #

Work Center

Control Key

Description

10

T-M##

PP01

Material Staging

20

T-E##

PP01

Pre-assemble pump

30

T-P##

PP01

In-process inspection

40

T-P##

PP01

Final assembly

50

T-P##

PP99

Deliver to stock

Standard Processing Times Activity

Op 10

Op20

Op 30

Op 40

Op 50

Setup

10 Min

30 Min

0 Min

30 Min

0 Min

Machine

0 Min

0 Min

0 Min

10 Min

0 Min

Labor

0 Min

10 Min

5 Min

10 Min

10 Min

2.

What are the task list group number and group counter on the header of your routing?

3.

What is the base quantity and operation unit for operation 10 and how does it relate to the standard values?

Task 4: Display your routing and answer the following questions.

2010

1.

Display your routing.

2.

What are the group number and group counter?

3.

When was the routing created and by whom?

4.

What are the validity dates for the routing?

5.

What are the validity dates of operation 20?

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Solution 9: Create a Simple Routing Task 1: Create a simple routing for material production. 1.

Create a routing for the production of material T-B## in plant 1000 that consists of the four steps in the table below. The routing should be creation status, valid from today’s date, for production usage, and for lot sizes from 1 to 100,000 Pc. Use the data in the table below to complete the routing information. Primary Operation Data Operation #

Work Center

Control Key

Description

10

T-A##

PP01

Lathe casing according to drawing

20

T-B##

PP01

Drill holes

30

T-C##

PP01

Insert Flat gasket

40

T-C##

PP01

Inspect and deliver to stock

Standard Processing Times Activity

Op 10

Op 20

Op 30

Op 40

Setup

10 Min

3 Min

0 Min

0 Min

Machine

30 Min

10 Min

0 Min

0 Min

Labor

30 Min

10 Min

5 Min

10 Min

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Create or use transaction code CA01.

b)

Enter the material T-B## and plant 1000 and choose Enter

c)

Enter Usage 1 for Production, Status 1 for Creation Phase, Planner group 0##, and lot size of 1 to 100,000 Pc.

d)

Select the Operations Overview icon and enter the Primary Operation Data from the table. Respond to any system messages that appear.

e)

Select all operations and choose Details → Operation from the menu. Enter the Standard Operation Processing Times from the table and choose to navigate to the next operation detail screen. Continue until all times have been entered and then choose to return to the operation overview.

.

Continued on next page

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2.

What are the task list group number and group counter on the header of your routing? a)

3.

Choose to view the header. The group number should be blank and the group counter is 1.

What is the base quantity and operation unit for operation 10 and how does it relate to the standard values? a)

From the operations overview, double-click on the operation number 0010. You should now be in the details of the operation. The base quantity is 1 PC. The standard values are the setup and labor times required to produce 1 casing.

b)

Save your routing by choosing Save

.

Task 2: Display your routing and answer the following questions. 1.

Display your routing. a)

2.

What are the group number and group counter? a)

3.

In the header details, scroll to the bottom of the screen. In the administrative data section, you will find today’s date for the creation date and your logon as the creator.

What are the validity dates for the routing? a)

5.

The group number will vary, but should be a number beginning with 50000 and the group counter should still be 1.

When was the routing created and by whom? a)

4.

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03. Enter T-B## and plant 1000 and choose .

The validity dates should be from today to 12/31/9999 as found in the administrative data section.

What are the validity dates of operation 20? a)

Select the Operations Overview button and double-click on operation number 20. Scroll to the bottom of the Operation details screen and you will see validity dates identical to those on the header: from today’s date to 12/31/9999.

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Task 3: Create a non-material-specific group routing to manufacture many different pumps that all have the same manufacturing process. 1.

Create a non-material specific routing for the production of several different pumps in plant 1000 thath all use the same five steps in the table below. The routing should be creation status, valid from today’s date, for production usage, and for lot sizes from 1 to 100 only. Use the data in the table below to complete the routing information. Primary Operation Data Operation #

Work Center

Control Key

Description

10

T-M##

PP01

Material Staging

20

T-E##

PP01

Pre-assemble pump

30

T-P##

PP01

In-process inspection

40

T-P##

PP01

Final assembly

50

T-P##

PP99

Deliver to stock

Standard Processing Times

Continued on next page

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2.

Activity

Op 10

Op20

Op 30

Op 40

Op 50

Setup

10 Min

30 Min

0 Min

30 Min

0 Min

Machine

0 Min

0 Min

0 Min

10 Min

0 Min

Labor

0 Min

10 Min

5 Min

10 Min

10 Min

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Create or use transaction code CA01.

b)

Make sure the Material field is blank, enter plant 1000, enter PUMP## in the Group field, and choose Enter .

c)

Enter Usage 1 for Production, Status 1 for Creation Phase, Planner group 0##, and lot size of 1 to 100,000 Pc.

d)

Select the Operations Overview button and enter the Primary Operation Data from the table. Respond to any system messages that appear.

e)

Select all operations and choose Details → Operations from the menu. Enter the Standard Operation Processing Times from the table and choose to navigate to the next operation detail screen. Continue to return to the until all times have been entered and then choose operation overview.

What are the task list group number and group counter on the header of your routing? a)

3.

Choose to view the header. The group number should be PUMP## and the group counter is 1.

What is the base quantity and operation unit for operation 10 and how does it relate to the standard values? a)

From the operations overview, double-click on the operation number 0010. You should now be in the details of the operation. The base quantity is 1 PC. The standard values are the setup time required to produce 1 pump.

b)

Save your routing by choosing Save

.

Task 4: Display your routing and answer the following questions. 1.

Display your routing. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03. Make sure the material field is blank and enter plant 1000, group PUMP##, and choose . Continued on next page

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What are the group number and group counter? a)

3.

When was the routing created and by whom? a)

4.

The validity dates should be from today to 12/31/9999, as found in the administrative data section.

What are the validity dates of operation 20? a)

278

In the header details, scroll to the bottom of the screen. In the administrative data section you will find today’s date for the creation date and your logon as the creator.

What are the validity dates for the routing? a)

5.

The group number should still be PUMP## and the group counter should still be 1.

Select the Operations Overview button and double-click on operation number 20. Scroll to the bottom of the operation details screen and you will see validity dates identical to those on the header: from today’s date to 12/31/9999.

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Lesson: Overview of the Task List

Lesson Summary You should now be able to: • Describe the different types of task lists • Describe the integration points of the task list

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Creating a Routing and Material Assignment Lesson Duration: 30 Minutes

Lesson Overview In this lesson, you will learn how to assign materials to routings, allocate materials components to specific operations on the routing, and to specify the dimensions of variable-size components.

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

Assign manufactured items to routings Allocate material components to operations Maintain cutting measures of variable-size items

Describe the life cycle process and use of the Routing

Business Example As a production planner you are responsible for the correct staging of material components for each operation in production. Therefore you have to assign these components to operations and, if necessary, adjust the BOMs.

Material Assignment You use this function to determine which material is to be produced with a routing or rate routing. On the basis of this assignment, the routing can be used for sales and operations planning, material requirements planning, creating production orders and product costing for this material. A material master record must exist in the system for the material that is to be produced. It must have a material type that is allowed for assignment to a routing or rate routing. Materials can be linked to routings for the following scenarios:

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Figure 92: Multiple Products - One Routing

The same routing can be used to produce several different materials. Each product has its own unique bill of material but is manufactured by a common set of activities with the same standard times. For example, both red and green chairs can be produced using the same routing. The material and routing can belong to different plants, for example, the planning plant and the production plant may not be the same. The material assignment can be done three different ways. You can create the routing for a specific material, use the material assignment functionality in the routing header, or you can use a production version. If you create a routing for a specific material the material assignment is automatically done by the system. No further settings are necessary and every order created finds this routing assignment and uses the appropriate routing to create the order. This process will be discussed further in the routing configuration lesson. If you have created a non-material specific routing or a group routing you can use the material assignment. In the header of the routing, the material assignment button will show you a list of all materials that are assigned to use this routing for their production. It allows you to assign more materials to the list. This is also effective for using a routing created for one material to produce a different material. The assignment could be for a material in a different plant, which allows you to plan production in one plant and produce in another.

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The third option is to use a production version. A production version specifies the production technique that can be used to produce a material. It specifies the BOM and routing used for production with date and lot size validities. In this case you must also set the selection method field on the MRP4 view of the material master to select by production version.

Component Allocation Component allocation determines when materials are to be made available to production and consumed in your production process. The shop floor papers will indicate the work center and time to deliver the component to the specific operation to which it was assigned. As production is completed and confirmations are recorded this allocation will also control the consumption of the components.

Figure 93: Material Assignment

The following data must already exist in the system: • • •

The operations in the routing. The master record for the material to be produced. The bill of material (BOM) for the material to be produced.

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

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You can • • •

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

Material components in a BOM that are not assigned to an operation in the routing are automatically assigned (default) to the first operation when you create a production order. Each item on the BOM can be assigned to only one operation. Items which have quantities of more than one and need to be assigned to more than one operation will need to be adjusted in the BOM to allow this type of allocation. For example, BOM item 10 has 2 pieces one of which is used at operation 20 and the other at operation 40. This will necessitate splitting BOM item 10 into 2 BOM items each with quantity of one, say item 10 and item 15. Then item 10 can be allocated to operation 20 and item 15 can be allocated to operation 40. According to the item category of the assigned components you can make further decisions about their processing, for example, backflushing of stock items or cutting size of variable-size items (discussed in next section). By repeating this process, you can assign material components from several BOMs or alternative BOMs to the same routing . In this case, when you create a production order, you select the BOM and thus which material components are to be assigned in the production order. The system can do this automatically, depending on the system settings.

Variable-Size Item Calculations in the Routing 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.

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Figure 94: Variable Size Items

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Exercise 10: Material Assignment and Component Allocation Exercise Duration: 15 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Assign materials to routings • Assign material BOM components to specific operations on the routing • Enter dimensions for variable sized components

Business Example Several different models of pumps use the same manufacturing steps in production and can use the same routing. You need to assign materials T-F1## and T-F2## to your PUMP## group routing. To make the manufacturing process more efficient, you want to assign material components from the BOM to specific operations on the routing to ensure they are delivered to the correct work center at the correct time. One of your components is a variable sized item and needs to have the specific dimensions defined.

Task 1: Display the material assignment of your T-B## routing. 1.

Display the material assignment for your T-B## routing.

Task 2: Assign materials to your group routing. 1.

Assign the materials T-F1## and T-F2## to your group routing PUMP##.

Task 3: Assign material components from the BOM to specific operations on the routing. 1.

First, create a plant-specific BOM for T-B## in plant 1000. Use the BOM T-B1## as a template.

2.

Assign material components from the BOM of T-B## to specific operations on the routing. Assign components T-T2## and T-T3## to operation 30.

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Task 4: Assign components to specific operations on your group routing. 1.

286

Assign the material components from T-F1## to specific operations on your group routing PUMP##. Assign components T-B1## and T-T3## to operation 40, and T-B2##, T-B3##, and T-B4## to operation 20 of your group routing PUMP##.

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Solution 10: Material Assignment and Component Allocation Task 1: Display the material assignment of your T-B## routing. 1.

Display the material assignment for your T-B## routing. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Display or use transaction code CA03.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

Select the Header icon

d)

Choose the Material Assignment icon.

e)

In the dialog box that appears, you will see your material, T-B##, plant 1000, listed in the table as assigned to use this routing.

.

to go to the header details.

Task 2: Assign materials to your group routing. 1.

Assign the materials T-F1## and T-F2## to your group routing PUMP##. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Leave material blank, enter plant 1000, group PUMP##, and choose Enter .

c)

Select the Header icon

d)

Choose the Material Assignment icon.

e)

In the dialog box that appears, enter Group counter 1, material T-F1##, and plant 1000 on the first line in the table.

f)

Enter Group counter 1, material T-F2##, and plant 1000 on the second line in the table.

g)

Choose Continue

h)

Choose Save

to go to the header details.

and both materials are assigned to use this routing.

to save your routing and exit.

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Task 3: Assign material components from the BOM to specific operations on the routing. 1.

First, create a plant-specific BOM for T-B## in plant 1000. Use the BOM T-B1## as a template. a)

2.

Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create or use transaction code CS01 . Enter the data from the table below. Field

Entry

Material

T-B##

Plant

1000

Usage

1

Valid from

Today’s date

b)

Select the Copy from icon

c)

In the Copy From.. dialog box, enter the material T-B1##, plant 1000, and BOM Usage 1 and choose Enter .

d)

Select all of the components to copy and choose Copy

e)

Save the BOM by choosing

.

again.

.

Assign material components from the BOM of T-B## to specific operations on the routing. Assign components T-T2## and T-T3## to operation 30. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

Select the Component Allocation icon.

d)

Select items T-T2## and T-T3## from the BOM that appears. Choose the New Assignment icon.

e)

You can enter operation 30 in the activity field or choose Oper./act. list icon to select the operation from a list.

f)

Choose Continue

g)

Choose Save

.

.

to save your routing and exit.

Continued on next page

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Task 4: Assign components to specific operations on your group routing. 1.

2010

Assign the material components from T-F1## to specific operations on your group routing PUMP##. Assign components T-B1## and T-T3## to operation 40, and T-B2##, T-B3##, and T-B4## to operation 20 of your group routing PUMP##. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Leave material blank, enter plant 1000, group PUMP##, and choose Enter .

c)

Choose the Component Allocation icon.

d)

A dialog box appears showing a list of all materials that are assigned to that routing. Choose T-F1## by clicking on the line in the table and choose .

e)

Select items T-B1## and T-T3## from the BOM that appears. Choose the New Assignment icon.

f)

You can enter operation 40 in the activity field, or choose Oper./act. list icon to select the operation from a list.

g)

Choose Continue and repeat steps e through f to assign components T-B2##, T-B3##, and T-B4## to operation 20.

h)

Choose Save

i)

If you want, you can repeat the above procedure to make component assignment for the T-F2## BOM to your PUMP## group routing.

to save your routing and exit.

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

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Lesson: 245

Lesson: Suboperations and User-Defined Fields

Suboperations and User-Defined Fields Lesson Duration: 25 Minutes

Lesson Overview In this lesson, you will learn how to use suboperations for more detailed planning and how user-defined fields can be used to add information to the routing and order.

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

Describe the functions of suboperations Retrieve additional fields in operations

Introduce the concept of suboperations and how they will be used in business practice.

Business Example As a production planner, you are responsible for routing management in the project team. You would like to model more detailed capacity constraints in your manufacturing process. You have several materials that require the use of specific tools during production. You would like to use suboperations to model these material specific constraints. You also need to use user-defined fields for transferring data in the operation from other systems.

Suboperations Suboperations are subordinate to an operation and used for more detailed planning of the process step that is described in the operation. They are typically used to carry out more detailed planning for capacity or costing for an operation. For example, you can use suboperations to assign several people or machines that are required at the same time, to an operation. A suboperation can be costed, but can only be scheduled relative to the superior operation. You can cumulate standard values from suboperations on the corresponding operation. You can determine whether suboperations belonging to an operation are copied into the production order.

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Figure 95: Suboperations

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. The control key has an important influence on this process. When using suboperations, it is important that you ensure costs and capacity requirements are not calculated twice.

Figure 96: Scheduling Suboperations

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Lesson: Suboperations and User-Defined Fields

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

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

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. An operation that is not to be carried out in the plant in the operation or routing can be assigned to another plant. The plants only have to belong to the same controlling area. A suboperation can be assigned to another plant as its superior operation. The unit of measure in the suboperation can differ from the one in the operation. You cannot assign material components, production resources/tools nor inspection characteristics to suboperations, only to operations.

User Defined fields in the Routing You can use user-defined fields to assign data fields to an operation or suboperation. You define the usage and meaning of these data fields yourself. You can enter business information or values for formula parameters that are not included in the standard system.

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Figure 97: User-Defined Fields

Depending on the field key, up to twelve data fields with various field formats are available. These are: • •

• • •

Up to four general fields for any text You can use them to store information about people responsible, substitutes or telephone numbers, for example. Up to two quantity fields You can assign additional formula parameters to the quantity fields in the field key. With the help of formula parameters you can use the values of the quantity fields in work center formulas, to calculate processing times, capacity requirements and costs. In addition, there is also a field for the unit of each quantity field. Default values and their units which you have maintained in Customizing for formula parameters are transferred, but you can change this data. If you have entered data in the quantity fields and then change the field key, the old values remain unchanged. Up to two value fields – In addition there is also a field for the unit of each value field. Up to two date fields – Here you can enter internal start dates, for instance. Up to two check boxes – You can use these to indicate whether an operation is to be included in evaluations in the Info System, for instance.

A field key is defined in Customizing for routings, in which the required combination of user-defined fields is stored. By assigning a field key to an operation or suboperation, you determine which user-defined fields are available in the particular object and also which field names or key words are used for these fields You can then enter data in these user-defined fields. Note that the system does not check for data validity.

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User-Defined Fields in Operations The configuration of user-defined fields has been moved from the appendix to this lesson where the functionality is discussed. Additional rouitng configuration topics can be found in the appendix. User-defined field keys are used to add data entry fields for user data to the operation detail screen. These field keys can offer the following fields: Quantity

Field type

2

Text (20 characters)

2

Text (10 characters)

2

Date

2

Quantity and unit of measure (can also be used by assignment to a parameter
 of origin 4 in formulas)

2

Value and/or currency

2

Checkboxes

Figure 98: User-Defined Fields

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In Customizing, the user first creates a field key name, then enters the 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.

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Exercise 11: Suboperations for Material-Specific Capacity Constraints Exercise Duration: 10 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Model detailed capacity planning for an operation using suboperations • Create suboperations • Accumulate the standard values of the suboperations in the superior operation

Business Example One of the operations in your production process consists of several steps that need to be planned in more detail for capacity. You want to use suboperations to do this.

Task 1: Use suboperations to model more detailed planning of operation steps. 1.

In the production of T-B##, operation 20 has several steps that must be capacity planned in more detail. Create four suboperations to model the detail capacity of this operation using the data in the table below. Subop

Description

Setup Machine

Labor

Ref Date to Start

Offset to start

10

Setup

3 Min

0 Min

0 Min

01

0 Min

20

Mill Pump casing

0 Min

15 Min

15 Min

02

0 Min

30

Turn pump casing 0 Min

10 Min

10 Min

02

15 Min

40

Deburr pump casing

10 Min

10 Min

02

25 Min

0 Min

Task 2: Accumulate the standard values of the suboperations in the superior operation. 1.

In your routing for T-B##, first check the standard values in the superior operation 20. Continued on next page

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2.

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In your routing for T-B##, accumulate the standard values of the sub-operations in the superior operation 20.

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Solution 11: Suboperations for Material-Specific Capacity Constraints Task 1: Use suboperations to model more detailed planning of operation steps. 1.

In the production of T-B##, operation 20 has several steps that must be capacity planned in more detail. Create four suboperations to model the detail capacity of this operation using the data in the table below. Subop

Description

Setup Machine

Labor

Ref Date to Start

Offset to start

10

Setup

3 Min

0 Min

0 Min

01

0 Min

20

Mill Pump casing

0 Min

15 Min

15 Min

02

0 Min

30

Turn pump casing 0 Min

10 Min

10 Min

02

15 Min

40

Deburr pump casing

10 Min

10 Min

02

25 Min

0 Min

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

Overwrite operation number 0050 with 0020, then enter suboperation number 10, work center T-B##, and the description from the table above.

d)

Select the suboperation and choose Details → Operation to enter the standard values and offset information. You may have to scroll down in the details to enter the offset.

e)

Repeat this procedure for each suboperation and save your routing.

.

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Task 2: Accumulate the standard values of the suboperations in the superior operation. 1.

2.

300

In your routing for T-B##, first check the standard values in the superior operation 20. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

To check the standard values of the superior operation 20, select the operation and choose Details → Operation. Make note of the values for Setup, Machine, and Labor.

.

In your routing for T-B##, accumulate the standard values of the sub-operations in the superior operation 20. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-B##, plant 1000, and choose Enter

c)

In the operation overview, select the superior operation 20.

d)

Choose Extras → Summarize standard values.

e)

Now check the standard values of the superior operation 20 to see if they have been updated. Select operation 20 and choose Details → Operation. You will see that the standard values have been updated from the accumulated totals of the suboperations.

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

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Reporting and Mass Changes Lesson Duration: 15 Minutes

Lesson Overview In this lesson you will learn the reporting options for routings and how mass changes can be accomplished.

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

Demonstrate how to make changes with history Demonstrate how to use where-used lists and mass changes

Business Example In the project team, you are responsible for the where-used lists and the mass changes in routing management. Your company must document the changes in its routings. You are responsible for ensuring changes are documented with history.

Change with a Change Master Record Changes without history 
 hanges without history do not have to be documented because they take C place during the development stage of the product, for example. The status of the object prior to the change is not saved. The system documents the changes that have taken place but you can only find out indirectly about the status of the object before the change.

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Changes with history 
Changes with history must be documented because they take place during production. Both the status before and after the change is saved. The system creates change documents. For some objects, these change documents differ from those created for changes without history. Engineering change management in the SAP system enables you to fully document changes. Some of these changes may be needed for product liability purposes, for example.

Figure 99: 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. 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.

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Figure 100: Why Use Engineering Change Management?

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. 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. As of release 4.0, there are other types of parameter effectivity besides date, for example, serial number, time interval, customer. These topics are discussed in more detail in the PLM150 – Engineering Change Management course.

Reporting and Mass Changes You can use the overview variant to control the information in the list and the order in which it is listed (for example, sequence, operation, component, PRT). You can create various displays for routings using object overviews. You can define your own object overviews in configuration in the IMG.

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Figure 101: Reporting Variants

By generating where-used lists, you can display the routings which use particular work centers, reference operation sets, reference rate routings, and production resources/tools (PRTs). You may need this information if you want to delete a work center or reference operation set but you want to first check if it is being used in a routing. If you want, you can also display routings which have already been deleted online but which still exist in the database.

Figure 102: Where-Used Lists

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

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Figure 103: Mass Change and Reporting

If you want to replace an object in several routings with another object (for example, an old work center with a new one) you can use the mass replace function. You do not have to generate a where-used list in order to replace each work center individually. Instead, you can use the mass replace function to quickly and completely replace work centers in all routings where they are used. You can use the Replace function to make mass changes to the following: • • •

Work centers PRTs Reference operation sets

The system generates a list of all routings that use the object to be replaced. When you use the mass replace function without a change number, the new objects will have the same validity periods as the old objects.

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Figure 104: Mass Replacement of Routing Data

You can use the replace function to make mass changes to work centers, PRTs, and reference operation sets.

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Lesson: Reporting and Mass Changes

Exercise 12: Task List Changes with ECM Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Make changes without history in a task list • Make changes with history in a task list • Display changes with history in a task list • Make mass changes with history in a task list

Business Example As new work centers are created to update your production equipment, task lists will also need to be updated. This may require changes to be captured with history for legal or reporting purposes. These changes also may need to be made in mass for all routings.

Task 1: Display a list of all changes without history that have been made to your routing. 1.

Display a list of changes that have been made to your routing, T-B##, thus far.

Task 2: Check to see which routings and rate routings are using a specific work center. 1.

Determine to which other task lists work center T-B## has been assigned by executing a work center where-used list.

Task 3: Because of a capacity constraint in your production, your company is building a new work center that will be operational in two months. Replace the final assembly work center in your routing effective on that day and be sure to track history. 1.

Replace the final assembly work center T-C## on your T-B## routing, with your new work center CENTER## using your Engineering Change Number ECN## to track history.

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Task 4: Display your routing with different key dates to view the change history. 1.

Display your routing with a key date one day before the change date (today + 2 months - 1 day). Which work center is assigned to operation 40? What are the validity dates of operation 40?

2.

Display your routing using a key date of one day after the change date (today + 2 months + 1 day). Which work center is assigned to operation 40? What are the validity dates of operation 40?

Task 5: Since the new work center will replace the old one on all routings, do a mass replace with history. 1.

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Your new work center, CENTER## , will replace work center T-F## on all routings two months from today. Use mass replace and change number ECN## to track history.

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Solution 12: Task List Changes with ECM Task 1: Display a list of all changes without history that have been made to your routing. 1.

Display a list of changes that have been made to your routing, T-B##, thus far. a)

Choose Logistics → Production → Master Data → Routings → Routings → Reporting → Task List Changes or use transaction code CA60.

b)

Enter task list type N, material T-B##, and plant 1000. Accept the default dates, be sure that all changes in the list are selected, and choose Execute .

c)

This is the list of changes that have been made to your routing. Look at the Changed on date and Changed by field.

Task 2: Check to see which routings and rate routings are using a specific work center. 1.

Determine to which other task lists work center T-B## has been assigned by executing a work center where-used list. a)

Choose Logistics → Production → Master Data → Routings → Routings → Reporting → Where-Used List → Work Center or use transaction code CA80.

b)

Enter the work center T-B## and plant 1000. Accept the default key date, enter task list type N in the from field, S in the to field to check all routings and rate routings, and choose Execute .

c)

Choose an overview variant from the list that displays work centers like L00000000060 and choose Enter. The system displays a list of all routings and rate routings that have the work center assigned, as well as the sequence and operation to which it is assigned.

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Task 3: Because of a capacity constraint in your production, your company is building a new work center that will be operational in two months. Replace the final assembly work center in your routing effective on that day and be sure to track history. 1.

Replace the final assembly work center T-C## on your T-B## routing, with your new work center CENTER## using your Engineering Change Number ECN## to track history. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings→ Change or use transaction code CA02.

b)

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

c)

A warning message appears in the status bar indicating, “The key date is overwritten with the date from the change number record.” Press ENTER to work through the warning.

d)

In operation 40, replace work center T-C## with CENTER## and save your routing.

e)

Why does the system require you to enter Machine Time? When you created the work center you assigned the rule Must be Entered. Since the previous work center did not have machine time defined it requires you to complete the data.

Task 4: Display your routing with different key dates to view the change history. 1.

Display your routing with a key date one day before the change date (today + 2 months - 1 day). Which work center is assigned to operation 40? What are the validity dates of operation 40? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings→ Display or use transaction code CA03.

b)

Enter the material T-B##, plant 1000, key date one day before the change date (today + 2 months - 1 day), and choose Enter .

c)

The work center assigned to operation 40 is T-C##.

d)

Double-click on the operation number and scroll to the bottom of the operation details screen to see the validity dates. The Valid To date should be the change date used in the change number or two months from today. Continued on next page

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2.

Display your routing using a key date of one day after the change date (today + 2 months + 1 day). Which work center is assigned to operation 40? What are the validity dates of operation 40? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings→ Display or use transaction code CA03.

b)

Enter the material T-B##, plant 1000, key date one day before the change date (today + 2 months - 1 day), and choose Enter .

c)

The work center assigned to operation 40 is CENTER##.

d)

Double-click on the operation number and scroll to the bottom of the operation details screen to see the validity dates. The Valid From date should be the change date used in the change number or two months from today.

Task 5: Since the new work center will replace the old one on all routings, do a mass replace with history. 1.

Your new work center, CENTER## , will replace work center T-F## on all routings two months from today. Use mass replace and change number ECN## to track history. a)

Choose Logistics → Production → Master Data → Routings → Extras → Mass Changes→ Replace Work Center or use transaction code CA85.

b)

Enter the work center T-F##, plant 1000, new work center CENTER##, plant 1000, change number ECN##, and choose Execute .

c)

A warning will appear to warn you that the work centers have different standard value keys. This can be important for formula calculations in the work center and affect capacity requirements, scheduling, and costing.

d)

On the list, select the operations for which you want to replace the work center and choose Replace work center . You will be required to enter machine time for each operation that does not have it.

e)

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Check the routings you just changed to see the change and the validity date.

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Lesson Summary You should now be able to: • Demonstrate how to make changes with history • Demonstrate how to use where-used lists and mass changes

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Unit Summary

Unit Summary You should now be able to: • Describe the different types of task lists • Describe the integration points of the task list • Assign manufactured items to routings • Allocate material components to operations • Maintain cutting measures of variable-size items • Describe the functions of suboperations • Retrieve additional fields in operations • Demonstrate how to make changes with history • Demonstrate how to use where-used lists and mass changes

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Unit Summary

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Test Your Knowledge

Test Your Knowledge 1.

Which of the following is not a way to create routing material assignments in SAP ERP? Choose the correct answer(s).

2.

□ □

A B

□ □

C D

Create a material specific routing Copy a materials master record and the BOM and routing are automatically copied also In the routing header create a material assignment Create a production version

Which of the following is not a pre-requisite for component allocation? Choose the correct answer(s).

□ □ □ □ 3.

A B C D

Operations in the routing must exist Production version must exist BOM for the material to be produced must exist Backflush indicator must be set

Any materials component that is not assigned to an operation in the routing will default to the first operation. Determine whether this statement is true or false.

□ □ 4.

True False

Each item on the BOM can be assigned to one and only one operation on the routing. Determine whether this statement is true or false.

□ □ 5.

True False

Component allocation to an operation is the only additional information which can be maintained with regard to components. Determine whether this statement is true or false.

□ □ 6.

True False

Suboperations can be used for more detailed capacity planning and costing. Determine whether this statement is true or false.

□ □

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True False

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7.

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When using suboperations costing is automatically done at the operation level regardless of the control keys. Determine whether this statement is true or false.

□ □ 8.

True False

You can use user-defined fields to assign data fields to an operation or suboperation for information purposes only. Determine whether this statement is true or false.

□ □ 9.

True False

Which of the following are ways to make changes to routings in SAP ERP? Choose the correct answer(s).

□ □ □ □

A B C D

Without record of changes With change documents With history using ECM All of the above

10. A where-used list can show you which task lists will be affected by a change in work center. Determine whether this statement is true or false.

□ □

True False

11. It is not possible to make mass changes to routings using an ECM number. Determine whether this statement is true or false.

□ □

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True False

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Test Your Knowledge

Answers 1.

Which of the following is not a way to create routing material assignments in SAP ERP? Answer: B There are 3 ways to create material assignments in the routing; create a material specific routing, create a material assignment in the header of the routing, create a production version. Material master records that are copied do not copy the BOM and routing also.

2.

Which of the following is not a pre-requisite for component allocation? Answer: B, D Before you can allocate components to specific operations on the routing the operations must exist in the routing and the BOM must exist for the material to be produced.

3.

Any materials component that is not assigned to an operation in the routing will default to the first operation. Answer: True Material components in a BOM that are not assigned to an operation in the routing are automatically assigned (default) to the first operation when you create a production order.

4.

Each item on the BOM can be assigned to one and only one operation on the routing. Answer: True Each item on the BOM can be assigned to only one operation. Items which have quantities of more than one and need to be assigned to more than one operation will need to be adjusted in the BOM to allow this type of allocation.

5.

Component allocation to an operation is the only additional information which can be maintained with regard to components. Answer: False According to the item category of the assigned components you can make further decisions about their processing, like backflushing of stock items or cutting size of variable-size items.

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6.

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Suboperations can be used for more detailed capacity planning and costing. Answer: True Suboperations are subordinate to an operation and used for more detailed planning of the process step that is described in the operation. They are typically used to carry out more detailed planning for capacity or costing.

7.

When using suboperations costing is automatically done at the operation level regardless of the control keys. Answer: False When using suboperations, it is important that you ensure costs and capacity requirements are not calculated twice by using the appropriate control keys.

8.

You can use user-defined fields to assign data fields to an operation or suboperation for information purposes only. Answer: False You can use user-defined fields to assign data fields to an operation or suboperation. You can enter business information or values for formulas parameters that are not included in the standard system. The values for formula parameters could be used for calculating capacity requirements, scheduling, or costing.

9.

Which of the following are ways to make changes to routings in SAP ERP? Answer: D Changes to routing can be made without history, with changes documents, or with history using ECM.

10. A where-used list can show you which task lists will be affected by a change in work center. Answer: True A where-used list can show you which task lists contain a specific work center and will be affected by a changed in that work center. 11. It is not possible to make mass changes to routings using an ECM number. Answer: False You can make changes to routings using mass change and by using an engineering change number.

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Unit 8 Advanced Bill of Material Functions

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In this unit you will demonstrate to the participants advanced functions of the bill of material. It is important that participants understand that not all funcations may be used in their implementation.

Unit Overview This unit introduces several advanced concepts surrounding the bill of material in SAP ERP. Not all of the following functions will be required to use during the modeling of your company’s manufacturing process. These functions will include the user of multiple bills of materials, co-products/by-products, substitute parts and other miscellaneous functions.

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

Explain the concept of a phantom BOM and when it should be used Create a phantom BOM in SAP R/3 Maintain phantom bills of material Demonstrate model co-products and by-products Demonstrate and explain the discontinuation process. Model item substitutions in the bill of material Discuss the advantages of using multiple and variant BOMs Create a multiple BOM Create a variant BOM Define variant configuration Update BOMs using mass changes Navigate the product structure browser

Unit Contents Lesson: Phantom Assemblies.................................................323

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Lesson: Co-Products and By-Products ......................................328 Exercise 13: Co-Products in Production Orders .......................331 Lesson: Discontinuation and Substitute Parts in the Bill of Material .....336 Exercise 14: Substitute Items in Production Orders ...................343 Lesson: Multiple and Variant BOMS..........................................352 Exercise 15: Multiple/Alternative Bills of Material ......................361 Exercise 16: Variant BOMs ...............................................371 Lesson: Mass Changes and the Product Structure Browser..............376 Exercise 17: Mass Changes and the Product Structure Browser....379

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Lesson: Phantom Assemblies

Phantom Assemblies Lesson Duration: 30 Minutes

Lesson Overview During the design or manufacturing of a product, engineering often times creates “phantom” or “dummy” assemblies. The purpose of these assemblies is to make maintenance of the item easier as the product evolves and changes.

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

Explain the concept of a phantom BOM and when it should be used Create a phantom BOM in SAP R/3 Maintain phantom bills of material

Business Example As a production planned, you have some parts that are categorized as service parts. These items are used in production, but are also sold directly to customers as the items’ wear and tear requires them to be replaced. You would like the item used in production to be classified as a phantom bill of material.

Phantom Assemblies A phantom assembly is a logical grouping of materials. A phantom assembly is usually created within engineering to describe a number of components easily and manage them as a whole. The components in a phantom assembly are placed immediately into the superior assembly. As opposed to this, components in an assembly are first assembled to produce the header material. After this, the header material is placed into the superior assembly. For example, the phantom assembly “set of wheels” contains the components “front wheel” and “rear wheel.” The front and rear wheels are placed immediately into the “bicycle” assembly. The “light” assembly contains the materials “bulb” and “reflector.” The light components are first assembled and then the light is attached to the bicycle.

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Figure 105: Phantom Assemblies

Phantom assemblies are used in SAP R/3 to enable the simple structuring of BOMs; the items typically do not physically exist. You can see phantom assemblies as parentheses around a group of components that are often used in conjunction with each other. This significantly reduces the amount of administration needed for the master data. For changes to materials (for example, discontinued material) you only have to carry out the changes on one BOM. The changes have an effect on all BOMs used by the phantom assemblies. Phantom assemblies also facilitate component assignment, since the components of a phantom assembly are assigned to the same operation. The same is true for the phantom assembly itself if you have not made an assignment for the components. During the BOM explosion in an SAP R/3 production order, the BOMs for phantom assemblies are also exploded. The components of the phantom assemblies become normal reservations, while the phantom assembly itself is transferred to the order as an unplanned effective reservation. The components of a phantom assembly are connected in a hierarchy with the superordinate assembly.

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Lesson: Phantom Assemblies

Figure 106: Setting Phantoms in SAP R/3

The settings for phantoms can occur in three different places in SAP R/3. The highest level to determine a part as a phantom assembly is at the material master. In the MRP 2 view, users can set an item to be a phantom assembly by setting the special procurement key. This means that this part at the plant level will not be manufactured and inventoried in that form. In addition, there are two settings that can be set in the bill of material for a component. In the details of the component, under the MRP section, users can use the explosion type or special procurement. The explosion type can switch the phantom assembly off for this BOM, and it will create a planned order for the item. This overrides the material master setting. Setting the special procurement key in the BOM to phantom assembly means that when this item is used in a the relevant BOM, it will be treated as a phantom. The settings in the BOM have priority over the material master since they are specific to a usage or manufacturing process.

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Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson Summary You should now be able to: • Explain the concept of a phantom BOM and when it should be used • Create a phantom BOM in SAP R/3 • Maintain phantom bills of material

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Lesson: 279

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Co-Products and By-Products Lesson Duration: 15 Minutes

Lesson Overview To model the manufacturing of multiple co-products, companies must consider the list of all BOM components that are necessary to effectively manage the yields and competing resources.

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

Demonstrate model co-products and by-products

Define and discuss the co-products and by-products. Explain the differences between them and how to make the appropriate settings.

Business Example During the machining of the casing for your pump, brass shavings are produced. These brass shavings are then sold back to the refiner who sold your company the brass ingot that was used in forging the casing. As a production planner your costing accounting group has asked you to model the brass shavings as a co-product in order to get the proper credit to manufacturing for the sale of the brass shavings. In addition to the brass, oil is used to cool the cutting blades during the machining process. The oil is collected and inventoried for proper disposal. This process is regulated by the government and has not value. Model the oil used for each casing as a by-product.

Co-Products in Manufacturing A co-product is a material that is manufactured simultaneously with the main product. In certain cases, the main material cannot be manufactured in isolation, without also producing the co-product, for a given production process.

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Lesson: Co-Products and By-Products

Figure 107: Manufacture of Co-Products

Use in ECC PP-PI Module: The process industry is full of numerous examples, where due to the nature of the chemical and biological reactions, there is a concurrent yield for multiple products. Typically there is one main product being manufactured. The rest of the products could be categorized as co-products, by-products, waste products. Co-products and by-products have a non-zero inventory valuation, as opposed to waste products having a zero unit cost. Furthermore, since the co-products label is given to products that have a higher cost visibility, then any other generic by-product in your company, the co-products are also earmarked for cost settlement at the end of the process order life cycle.

Figure 108: Co-Products in the BOM

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Main Leading Material and Co-Product - Structure: Co-products, by-products, and waste products are set up as a negative quantity components in the BOM of the Master Recipe. Since co-products have further cost settlements, a series of indicators have to be setup in the product masters and the BOM. All of the product masters, and the negative quantity components must have the co-product indicator fields check marked. Also the cost apportionment ratios for all of the cost components that are involved with the co-products, have to be defined in their product masters. To better understand Co-products we first must understand several related terms. All of these terms are used frequently in the Food, Chemicals, Electronics, and other process, repetitive and flow manufacturing industries. Co-product In ECC a co-product is a material that is manufactured simultaneously with the main product. The main material cannot be manufactured in isolation, without also producing the co-product, for a given production process. Co-products have a non-zero inventory valuation. Co-products are also earmarked for cost settlement at the end of the process order life cycle, and appear in the header settlement rule. By-product In ECC a by-product is a material that is manufactured simultaneously with the main product. The main material cannot be manufactured in isolation, without also producing the by-product, for a given production process. By-products have a non-zero inventory valuation. By-products are not earmarked for cost settlement at the end of the process order life cycle, and do not appear in the header settlement rule. Waste product In ECC a waste product is a material that is manufactured simultaneously with the main product. The main material cannot be manufactured in isolation, without also producing the waste product, for a given production process. Waste products have a zero inventory valuation. Waste products are not earmarked for cost settlement at the end of the process order life cycle, and just like by-products, do not appear in the header settlement rule.

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Lesson: Co-Products and By-Products

Exercise 13: Co-Products in Production Orders Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Explain how to set up co-products in SAP ERP

Business Example The stamping and assembly operations of the pump yields two additional gaskets which are not needed for the pump, but they have value. You need to put them into inventory.

Task 1: Define co-products on the BOM Caution: It is important not to skip this demo as it sets up the component T-DET-CNDST to be used as a co-product on the BOM. If this isn’t done then the student exercises will not work. Setup the Material Master for T-DET-CNDST to be used as a co-product. Change the MRP2 view by flagging the co-product indicator. and answer the following questions. Change the MRP2 view of the Material Master T-DET-CNDST, plant 3100, by flagging the co-product indicator. Menu Path:Logistics → Production - Process → Master Data → Material Master→ Material → Change → Immediately. Enter Material, T-DET-CNDST. Press Enter. You will see the Select Views pop-up. Select the MRP2 view and Press Enter. Enter Plant 3100. Press Enter again. Select the Co-product indicator, and press the Save icon. 1.

Define material T-G##, plant 1000 as a co-product on the BOM of pump T-F1##.

Task 2: Optional: Test the co-product setting 1.

2010

Create a production order for T-F1##. View the co-product results in the stock requirements list.

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Solution 13: Co-Products in Production Orders Task 1: Define co-products on the BOM Caution: It is important not to skip this demo as it sets up the component T-DET-CNDST to be used as a co-product on the BOM. If this isn’t done then the student exercises will not work. Setup the Material Master for T-DET-CNDST to be used as a co-product. Change the MRP2 view by flagging the co-product indicator. and answer the following questions. Change the MRP2 view of the Material Master T-DET-CNDST, plant 3100, by flagging the co-product indicator. Menu Path:Logistics → Production - Process → Master Data → Material Master→ Material → Change → Immediately. Enter Material, T-DET-CNDST. Press Enter. You will see the Select Views pop-up. Select the MRP2 view and Press Enter. Enter Plant 3100. Press Enter again. Select the Co-product indicator, and press the Save icon. 1.

Define material T-G##, plant 1000 as a co-product on the BOM of pump T-F1##. a)

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

b)

Enter the following data from the table below. Field

Entry

Material

T-F1##

Plant

1000

BOM Usage

1

c)

Choose Enter

d)

Enter the following in the first available component item on the General Item Overview screen.

.

Field

Entry

Component

T-G## Continued on next page

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Field

Entry

Quantity

2-

e)

Choose Enter

f)

Go to the item details by double-clicking the item number or highlighting the line and selecting the item icon (or pressing F7).

g)

On the Basic Data tab, select the Co-product indicator.

h)

Save the BOM.

.

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Task 2: Optional: Test the co-product setting 1.

Create a production order for T-F1##. View the co-product results in the stock requirements list. a)

Choose Logistics → Production → Production Control → Order → Create → With Material (CO01).

b)

Enter the following data and press ENTER.

c)

Field

Entry

Material

T-F1##

Plant

1000

Order Type

PP01

Enter only the following two items and choose Save. Field

Entry

Total Qty

10

Finish

Current date + 1 month

Hint: If a message regarding costs is displayed; choose Yes to continue and save the order.

334

d)

Choose Logistics → Production → MRP → Evaluations → Stock/Requirements List.

e)

Enter the data from the table below. Field

Entry

Material

T-G##

MRP Area



Plant

1000

f)

Choose Enter

g)

A production order has been created for the co-product to be received into inventory. The quantity has been calculated based on the BOM quantity.

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Lesson: Co-Products and By-Products

Lesson Summary You should now be able to: • Demonstrate model co-products and by-products

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Discontinuation and Substitute Parts in the Bill of Material Lesson Duration: 30 Minutes

Lesson Overview BOMs are seldom static. Component materials are replaced by other items. Certain components may also be substituted if the need arises. In this lesson, we will introduce discontinuation and alternative items as methods to manage such situations.

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

Demonstrate and explain the discontinuation process. Model item substitutions in the bill of material

Business Example In the manufacturing of several of your products, you use an extensive amount of wiring. The wiring is inventoried as several different part numbers, based on the grade of wire. In the event of an inventory shortage, engineering has authorized the use of higher grade wire in place of the standard item. As a production planner, you need to model this to assure that production orders can be completed when released to the shop floor. You want to model this substitution process in your bill of material.

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Lesson: Discontinuation and Substitute Parts in the Bill of Material

Item Substitution in the Bill of Material The engineering and design department may specify that a material is to be replaced by another at a particular point in time. These changes may be necessary for the following reasons: •

•

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

Discontinuation control works in the same way for long-term master production and requirements planning.

Figure 109: Discontinuation Control (Simple Discontinuation)

Discontinuation Control (Simple Discontinuation) Discontinuation control (Parallel Discontinuation) Show only the places relevant for maintenance in material master and BOM. Explain the effects of the maintenance. Simple Discontinuation: A component that is to be discontinued is replaced by a follow-up material as of a certain date, as soon as the stock available for MRP of the discontinued component is zero. This means that when the stock available for MRP of the discontinued material is zero, the dependent requirements are diverted from the discontinued material to the follow-up material. If the follow-up material is not available for MRP, the follow-up material is then acquired (in place of the discontinued material). The safety stock of the discontinued material is not affected by requirements planning.

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If the stock available for MRP for the discontinued material becomes greater than zero again, due to a later order for instance, the material is used again. An exception message for goods deliveries subsequent to the discontinued date is also produced. Prerequisites: In the material master record of the discontinued component, the discontinued indicator is set to 1, a follow-up material is entered, and a discontinued date is set. For information purposes, the follow-up material can be maintained in the BOM as a follow-up material.

Figure 110: Discontinuation Control (Parallel Discontinuation)

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

•

338

In the material master record of the main discontinued component, the discontinued indicator is set to 1 and the follow-up indicator 3 appears in the material master record of the dependent discontinued component. In the extras for the BOM item, define a discontinuation group under follow-up/discontinued dates; this freely definable character string contains a summary of the associated, discontinued items of a BOM. The main component to be discontinued and its dependent component are identified using the same discontinuation group.

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Lesson: Discontinuation and Substitute Parts in the Bill of Material

•

You can also define the follow-up component(s) using the follow-up item indicator. The succeeding group contains a summary of the associated follow-up items in a BOM; it determines by which follow-up items the discontinued items are to be replaced. The character string of the succeeding group must correspond with the character string of the discontinued group.

Figure 111: Alternative Items

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

Alternative items with specified usage probability These alternative items incorporate a certain usage probability. Create a usage probability for each alternative item in a group, so that in requirements planning a dependent requirement is created and this is changed to a reservation in the production order.

•

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You can also create an alternative item for information purposes, for instance, that is only referenced in missing part situations. As neither a dependent requirement nor a reservation will occur for this item, you do not produce a usage probability.

Figure 112: Alternative Item Data Detail Screen

•

Backflush according to usage probability For all items that are to be reserved, maintain the:

•

– Strategy (value 1 or no entry) – Ranking order (only affects the sorting of materials) – Usage probability Backflush at 100% availability For all items that are to be reserved, maintain the –

•

Ranking order; if no ranking order is entered, the system checks the items in the order in which they are transferred for availability check (value 1 or no entry) – Strategy (value 2) – Usage probability Backflush at 100% availability (strategy 2) With this strategy, the availability check is executed in the specified ranking order according to ATP logic. Gross requirements: 100 pieces

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• •

•

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Material

Usage Probability

Ranking

Planned Requirement Amount

ATP Q 
 uantity:

Backflush quantity

A

20

1

20

30

0

B

30

2

30

150

100

C

50

3

50

180

0

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

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Exercise 14: Substitute Items in Production Orders Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Enter alternative items on a BOM

Business Example Certain materials must be used as a substitute in case the standard material is not available.

Task 1: Optional: Components T-B1## and T-Z## are interchangeable parts that can both be used to produce the finished material T-F1##. In this situation we want to choose the component that has enough inventory to supply the entire production order. Create T-B1## and T-Z## as alternative items in the BOM T-F1##. 1.

Use the stock/requirements list to display the current stock available for the following materials: T-B1## T-B2## T-B3## T-B4## T-T3## T-Z## Change the stock for the above materials in plant 1000 at storage location 0001 to the following status: T-B1##

100 pieces (exact)

T-B2##

200 pieces (minimum)

T-B3##

200 pieces (minimum)

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T-B4##

200 pieces (minimum)

T-T3##

1800 pieces (minimum)

T-Z##

200 pieces (minimum)

Change the BOM of material T-F1## by adding the new component T-Z## as an alternative item to T-B1##. For item T-B1##, enter Alt.item group 01, Priority 1, Strategy 2, and Usage probability 100. For item T-Z##, enter Alt.item group 01, Priority 2, Strategy 2, and Usage probability 0.

Task 2: Optional: Using a production order, test the effects of the alternative item(s). 1.

Test the effects of the alternative item group on production planning and material backflush. Create a production order for the material T-F1## in plant 1000 for LESS THAN 100 pieces. Use the order category PP01. Select one month from today’s date as the order finish date. After confirming the data entries with ENTER, go to the component overview to find the answers to the following questions: ATP Check Status

Before ATP

After ATP

How high is the quantity requirement of T-B1##? How high is the confirmed quantity of T-B1##? How high is the quantity requirement of T-Z##? How high is the confirmed quantity of T-Z##? Caution: Do not save the order yet. 2.

Carry out an availability check for all components and complete the last column in the above table for the “After ATP Check” results. When finished, exit and do not save the order.

3.

Repeat the last two steps to test the effect of the alternative item groups in the case of insufficient stock. Create a production order for the material T-F1## in plant 1000 for MORE THAN 100 pieces. Use the order category PP01. Select one month from today’s date as the order finish date. After confirming your data entries with ENTER, go to the Component overview to find the answers to the following questions: Continued on next page

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Caution: Do not save the order at this point. ATP Check Status

Before ATP

After ATP

How high is the quantity requirement of T-B1##? How high is the confirmed quantity of T-B1##? How high is the quantity requirement of T-Z##? How high is the confirmed quantity of T-Z##? 4.

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Carry out an availability check for all components and complete the above table as you did before.

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Solution 14: Substitute Items in Production Orders Task 1: Optional: Components T-B1## and T-Z## are interchangeable parts that can both be used to produce the finished material T-F1##. In this situation we want to choose the component that has enough inventory to supply the entire production order. Create T-B1## and T-Z## as alternative items in the BOM T-F1##. 1.

Use the stock/requirements list to display the current stock available for the following materials: T-B1## T-B2## T-B3## T-B4## T-T3## T-Z## Change the stock for the above materials in plant 1000 at storage location 0001 to the following status: T-B1##

100 pieces (exact)

T-B2##

200 pieces (minimum)

T-B3##

200 pieces (minimum)

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T-B4##

200 pieces (minimum)

T-T3##

1800 pieces (minimum)

T-Z##

200 pieces (minimum)

a)

For analysis of current requirements/stock situation, choose Logistics → Production → MRP → Evaluations → Stock/Requirements List or use transaction MD04. Stock is displayed in the top line.

b)

For any necessary deliveries of goods, choose Logistics → Materials Management → Inventory Management → Goods Movement → Goods Receipt → Other or use transaction MB1C.

c)

Enter movement type 561, plant 1000, storage location 0001, today’s date as document and Posting Date, and leave the other fields empty or enter default differences.

d)

For any necessary issues of goods (in case a material has too much stock) choose Logistics → Materials Management → Inventory Management → Goods Movement → Goods Issue or use transaction MB1A.

e)

Use the movement category 201 and the cost center 1000.

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Change the BOM of material T-F1## by adding the new component T-Z## as an alternative item to T-B1##. For item T-B1##, enter Alt.item group 01, Priority 1, Strategy 2, and Usage probability 100. For item T-Z##, enter Alt.item group 01, Priority 2, Strategy 2, and Usage probability 0. a)

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

b)

In the first available row, enter item T-Z## with the quantity 1 piece.

c)

To set the items as alternative items, select both components on the General Item Overview screen and select Details .

d)

In the details for component T-B1##, enter AltItemGroup 01 and press ENTER.

e)

Enter the following in the Alternative Item Data dialog box. Field

Entry

Priority

1

Strategy

2

Usage Prob.

100

f)

Press ENTER and choose Next Item component T-Z##.

g)

In the details for component T-Z##, enter AltItemGroup 01 and press ENTER.

h)

Enter the following in the Alternative Item Data dialog box.

to proceed to the details for

Field

Entry

Priority

2

Strategy

2

Usage Prob.

0

i)

Press ENTER. Work through any warnings that appear by pressing ENTER.

j)

Save the BOM.

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Task 2: Optional: Using a production order, test the effects of the alternative item(s). 1.

Test the effects of the alternative item group on production planning and material backflush. Create a production order for the material T-F1## in plant 1000 for LESS THAN 100 pieces. Use the order category PP01. Select one month from today’s date as the order finish date. After confirming the data entries with ENTER, go to the component overview to find the answers to the following questions: ATP Check Status

Before ATP

After ATP

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

varies (ALL)

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

0

varies (ALL)

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

1

0

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

0

0

Caution: Do not save the order yet. a)

To create a production order, choose Logistics → Production→ Production Control→ Order→ Create→ With Material or use transaction code CO01.

b)

Enter the material number, plant, and order type on the initial screen and press ENTER.

c)

On the next screen, enter the total quantity and the order finish date of today + 1 month and press ENTER.

d)

Go to the Components overview using the above table.

button. Complete the

Caution: Do not save the order at this point. 2.

Carry out an availability check for all components and complete the last column in the above table for the “After ATP Check” results. When finished, exit and do not save the order. a)

Choose Availability Check for material.

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Repeat the last two steps to test the effect of the alternative item groups in the case of insufficient stock. Create a production order for the material T-F1## in plant 1000 for MORE THAN 100 pieces. Use the order category PP01. Select one month from today’s date as the order finish date. After confirming your data entries with ENTER, go to the Component overview to find the answers to the following questions: Caution: Do not save the order at this point. ATP Check Status

Before ATP

After ATP

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

0

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

0

0

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

1

varies (ALL)

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

0

varies (ALL)

a) 4.

Carry out an availability check for all components and complete the above table as you did before. a)

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Exit without saving the order.

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Lesson Summary You should now be able to: • Demonstrate and explain the discontinuation process. • Model item substitutions in the bill of material

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Multiple and Variant BOMS Lesson Duration: 40 Minutes

Lesson Overview Variant and multiple bills of material are a method to manage BOMs. We will discuss the circumstances and advantages of each.

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

Discuss the advantages of using multiple and variant BOMs Create a multiple BOM Create a variant BOM Define variant configuration

The objective is to teach the multiple and variant concepts. Many students get confused with “variant BOM’s” and Variant Configuration. For this reason it is necessary to define variant configuration. Details of variant configuration should be avoided. Definition only.

Business Example Two situations many occur that may increase the number of BOMs that need to be managed. First, a single material may have more then one list of components. We will use multiple BOMs to manage these. Second, many materials may use similar components. We will use variant BOMs for these. Multiple BOM - One Product Multiple BOM “M” Explain the meaning of multiple BOM. Explain when the multiple (alternative) BOM is used. Note: A maximum of 1000 alternatives are possible. Demonstration for multiple BOMs 10 minutes Use the exercise for the multiple BOM for your demonstration. Assign a name to the alternatives in the alternative text. For example: "Alternative + Material number + Maximum lot size" . 
Enter a description for the BOM group, for instance: Alternatives or Paints Show the differences and similarities when compared to variant BOMs.

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Comparison of Different Types of BOM Summarize the features of and differences between the individual technical BOM types. Optional exercise on multiple BOMs only 15 minutes

Multiple BOMs One product may be made of different combinations of components, depending on the quantity (lot size) to be manufactured or the date. This type of product is often represented by alternative BOMs (alternatives). These alternative BOMs differ only slightly from one another, usually in terms of the component quantity.

Figure 113: Multiple BOM: One Product

The field BOM group can also be used as an external BOM number. All alternatives for a multiple BOM are saved under one internal BOM number. You can assign one name to all the alternatives in a multiple BOM by entering a BOM group in the BOM header.

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Figure 114: Multiple BOM

The plant and usage are part of the unique key that identifies a BOM. Each alternative has a BOM header. The alternative is selected according to the selection method indicator in the material master record: • • •

Lot size Date Production version

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

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Variant BOMs If several similar products are manufactured whose parts only differ in minor ways, you can represent these various products using a variant BOM. Variants can also differ in component quantity alone.

Figure 115: Variant BOM: Several Products

Only a simple (basic) material BOM can be extended to become a variant BOM. You cannot convert a multiple BOM into a variant BOM.

Figure 116: Variant BOM

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You can create a variant only if: • •

A BOM does not already exist for the material. The base unit of measure of all variant materials is the same. This is because the base unit of measure of the bill of material must be the same as the base unit of measure of the material master record.

Figure 117: Variant BOM (2)

Several products created as variants of a variant BOM are saved under one internal BOM number. You can give a name to all of the variants of a variant BOM by entering a BOM group in the BOM header. Each variant has its own material number. The field BOM group can also be used as an external BOM number. The plant and the BOM usage are part of the unique key of a bill of material. Each variant has a BOM header. You can create a variant only if: • •

356

A BOM does not already exist for the material. The base unit of measure of all variant materials is the same. This is because the base unit of measure of the bill of material must be the same as the base unit of measure of the material master record.

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Figure 118: Different Types of BOMs

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

Variant Configuration When dealing with multivariant products, the combinations of individual product features give rise to a vast range of variants. Complex products mean complex configuration tasks in both sales and production. A company that sells or produces products with variants must perform these configuration tasks quickly and accurately.

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Figure 119: Variant Configuration

However, this is not easy, as product development cycles and life cycles of products are becoming shorter than ever before. Standard product is a general term used to define a product that is to be manufactured in multiple variants. It covers all the possible features of the variant product, and therefore does not refer to one specific article. The features of configurable products are defined the SAP system as characteristics.

Figure 120: Configuration of a Pump

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

Some combinations are not possible for technical reasons. Other combinations may not be allowed for marketing and sales reasons. For example, if you want to order a motorcycle, you may only be able to have certain colors of paint and seats if you are ordering an expensive model.

Instead of creating a separate BOM for each product variant, you can group the components together into a super BOM. This super BOM consists of parts that appear in all variants of the product, and others that can be chosen and included in the product depending on the variant. You use object dependencies to define which components are selected under which conditions. In the sales order, an individual product structure is created dynamically.

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Exercise 15: Multiple/Alternative Bills of Material Exercise Duration: 15 Minutes

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

Business Example You need to group together bills of material for “blue paint” in a multiple BOM.

Task: Maintaining Alternative/Multiple BOMs The BOM for “blue paint” (material number T-F77## (## = group number) has different components or component quantities for different lot sizes. 1.

Create a BOM for the paint in plant 1000 with the following data: Material T-F77##, BOM group Color-##, and BOM text ‘multiple BOM group ##’.

2.

Item

Item cat.

Component

Quantity

Un

10

L

T-B71

0,5

kg

20

L

T-B74

1

kg

30

L

T-B75

1

kg

Create an alternative by copying alternative 1. In this alternative, replace item 10, component T-B71, with the item below and change the quantity of item 20: Item

Item cat.

Component

Quantity

Un

10

L

T-B72

0.3

kg

Change the quantity of component T-B74 in item 20 to 1.4 kg. 3.

Create another alternative by copying alternative 1. In this alternative, replace item 10, component T-B71, with the following: Item

Item cat.

Component

Quantity

Un

10

L

T-B73

0.3

kg Continued on next page

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4.

5.

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

Alt text

Lot size from

to

1

Paint Color 1

1

100

2

Paint Color 2

101

200

3

Paint Color 3

201

500

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

6.

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

7.

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

362

Material

Plant

BOM usage

Valid from

BOM Alt

T-F77##

1000

1

01/01/xxxx

1

T-F77##

1000

1

01/07/xxxx

2

T-F77##

1000

1

01/12/xxxx

3

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Solution 15: Multiple/Alternative Bills of Material Task: Maintaining Alternative/Multiple BOMs The BOM for “blue paint” (material number T-F77## (## = group number) has different components or component quantities for different lot sizes. 1.

Create a BOM for the paint in plant 1000 with the following data: Material T-F77##, BOM group Color-##, and BOM text ‘multiple BOM group ##’.

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Item

Item cat.

Component

Quantity

Un

10

L

T-B71

0,5

kg

20

L

T-B74

1

kg

30

L

T-B75

1

kg

a)

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

b)

Enter the data from the table below. Field

Entry

Material

T-F77##

Plant

1000

Usage

1

Valid from

Today’s date

c)

Choose Enter

d)

On the Item overview screen, enter the following data:

.

Item

Item cat.

Component

Quantity

10

L

T-B71

0.5

20

L

T-B74

1

30

L

T-B75

1

e)

Give the BOM group a name:Paint-##.

f)

Go to the BOM Header

g)

In the BOM Group field, enter PAINT-##.

h)

Save the BOM.

.

Create an alternative by copying alternative 1. In this alternative, replace item 10, component T-B71, with the item below and change the quantity of item 20: Item

Item cat.

Component

Quantity

Un

10

L

T-B72

0.3

kg

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

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

b)

Enter the data from the table below. Entry

Material

T-F77##

Plant

1000

Usage

1

Valid from

Today’s date

c)

Select copy from

d)

Confirm the warning “Alternative 2 added to BOM.”

e)

Enter alternative 1 in the dialog box and choose Enter.

f)

Select all of the components to copy and choose Copy

g)

Change the following two rows in the item overview:

h) 3.

Field

or press F7.

again.

Item no.

Item cat.

Component

Quantity

10

L

T-B72

0.3 kg

20

L

T-B74

1.4 kg

Save the BOM

Create another alternative by copying alternative 1. In this alternative, replace item 10, component T-B71, with the following:

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Item

Item cat.

Component

Quantity

Un

10

L

T-B73

0.3

kg

a)

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

b)

Enter the data from the table below. Field

Entry

Material

T-F77##

Plant

1000

Usage

1

Valid from

Today’s date

c)

Select copy from

d)

Confirm the warning “Alternative 3 added to BOM.”

e)

Enter Alternative 1 in the dialog box and choose Enter.

f)

Select all of the components to copy and choose Copy

g)

Change the following in the item overview:

h) 4.

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or choose F7.

again.

Item no.

Item cat.

Component

Quantity

10

L

T-B73

0.3 kg

Save the BOM

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

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5.

Alternative

Alt text

Lot size from

to

1

Paint Color 1

1

100

2

Paint Color 2

101

200

3

Paint Color 3

201

500

a)

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

b)

Enter the data from the table below. Field

Entry

Material

T-F77##

Plant

1000

Usage

1

Valid from

Today’s date

c)

Select alternative 1 and select the Header icon

d)

On the Quantities/Long text tab page, (F6) add the following: Alt text. Paint Color 1 and lot size from 1 to 100.

e)

Repeat steps for alternatives 2 and 3.

.

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

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Technical type ____________ a)

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

b)

Enter the data from the table below.

c)

Field

Entry

BOM group

Paint-##

Plant

1000

Usage

1

Valid from

Today’s date

Choose Goto → Alternative overview. Three alternatives should now be displayed. Select all alternatives and choose the Header icon . Hint: Switch between the three different alternatives using the Next alternative icon

d)

.

BOM number, usage 1 and technical type M should be the same in all alternatives. Alternative texts and lot sizes should be different for each alternative (see defaults).

6.

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

Continued on next page

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Alternative ____ because ______________________________ a)

Choose Logistics → Production → Shop Floor Control → Order → Create → with material.

b)

Enter the data from the table below.

c)

d)

Field

Entry

Material

T-F77##

Production plant

1000

Order type

PP01

Choose Enter. Enter the following data. Total quantity

125

Order finish date

2 months from today

Choose Enter. Ignore the message “ no working schedule found .”

7.

e)

Choose generate process.

f)

On the Master data tab page, enter BOM Alt. quantity).

g)

Now change quantity to 225 pieces. Choose Functions → Read PP master data → Read BOM only. Enter BOM Alt. 3 (because of quantity).

h)

Exit the order without saving.

2 (because of

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

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Material

Plant

BOM usage

Valid from

BOM Alt

T-F77##

1000

1

01/01/xxxx

1

T-F77##

1000

1

01/07/xxxx

2

T-F77##

1000

1

01/12/xxxx

3

a)

In the IMG, transaction code SPROchoose Production → Basic Data → Bill of Material → Alternative Determination → Define Alternative Determination for Multiple BOMs. or use transaction code OS32.

b)

Maintain data as described in the table and Save.

c)

Change the Selection Method indicator in the Material Master by choosing Logistics → Production → Master Data → Material Master →Material → Change → Immediately or use transaction code MM02.

d)

Enter T-F77##, choose the MRP 4 View, and enter plant 1000.

e)

Set the Selection Method indicator to 1 Selection by Explosion Date and save.

f)

Test by creating a production order with different dates and check with alternative BOM was used as in the previous exercise.

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Lesson: Multiple and Variant BOMS

Exercise 16: Variant BOMs Exercise Duration: 20 Minutes

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

Business Example The engineering department requires BOMs to efficiently maintain simple but similar materials.

Task: You now want to create two additional variants of the pump T-F## in plant 1000 with where-used list 1. These are pumps T-FY## and T-FZ##. 1.

Create a BOM for pump T-FY## as a variant of T-F##. Replace component T-B## with T-B1##. Enter the following header data. BOM text

“Standard pump”

Alternative Text

Y variant and Z variant

BOM group

VA##

2.

Create a BOM for pump T-FZ## as a variant of T-F##. Replace component 100-300 with T-BZ##.

3.

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

4.

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BOM group

_______________

Internal BOM number

_______________

Technical type

_______________

Enter BOM item 100-801 in BOM group maintenance (any quantity you choose), which is only valid for variants T-FY## and T-FZ##. Check the result.

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Solution 16: Variant BOMs Task: You now want to create two additional variants of the pump T-F## in plant 1000 with where-used list 1. These are pumps T-FY## and T-FZ##. 1.

Create a BOM for pump T-FY## as a variant of T-F##. Replace component T-B## with T-B1##. Enter the following header data. BOM text

“Standard pump”

Alternative Text

Y variant and Z variant

BOM group

VA##

a)

Create an additional variant for pump T-FY##. Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create .

b)

Enter the data below. Material

T-FY##

Plant

1000

(Default)

Usage

1

(Default)

Valid from

Today’s date

(Default)
 do not press

c)

Choose Create variant of.... button .

d)

Enter Material T-F## in the Create variant of... dialog box. Choose Enter

.

e)

Select all components to be copied and choose the Copy icon

f)

Enter header data from the table below: BOM group

VA##

BOM text

Standard pump

.

Continued on next page

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Alt text

Y variant

Confirm with Enter. g)

h) 2.

In the Item Overview, change the component below: Item no.

Item cat.

Component

Quantity

10

L

100-100

1

Save the BOM.

Create a BOM for pump T-FZ## as a variant of T-F##. Replace component 100-300 with T-BZ##. a)

Create additional variant for pump T-FZ##. Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create .

b)

c)

Enter the following data. Material

T-FZ##

Plant

1000

(Default)

Where-used list

1

(Default)

Valid from

Today’s date

(Default)
 do not press

Choose Create variant of.... button. Enter Material T-F## in the Create variant of... dialog box.

d)

Choose Enter

e)

Select all components to be copied and choose the Copy icon

f)

In the Item Overview, change the component below:

g) 3.

. .

Item no.

Item cat.

Component

Quantity

30

L

T-BZ##

1

Save the BOM.

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

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BOM group

_______________

Internal BOM number

_______________

Technical type

_______________

a)

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

b)

Enter the following data. BOM group

VA##

Plant

1000

Valid From

Today’s date

Choose Enter. c)

Select Variants button.

d)

Select all variants and choose the Header button

.

BOM number, usage 1, and technical type V exist only once. Hint: In the header, choose : Item. You can then move between the individual variants using the Previous Variants and Next Variants buttons. In the summarized BOM, choose Variant items to view selected items. 4.

Enter BOM item 100-801 in BOM group maintenance (any quantity you choose), which is only valid for variants T-FY## and T-FZ##. Check the result. a)

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

374

b)

Enter BOM Group VA## and press ENTER.

c)

Enter component material 100-801 and a quantity in the first available component item, and set the Item indicator in alternative/variant 02 and 03 for variants T-FY## and T-FZ##.

d)

Save the BOM.

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Lesson Summary You should now be able to: • Discuss the advantages of using multiple and variant BOMs • Create a multiple BOM • Create a variant BOM • Define variant configuration

Related Information Variant configuration is taught in the following SAP courses: • • • • •

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PLM130 Classification PLM140 Variant Configuration 1 – Modeling PLM143 Variant Configuration 2 – Integration WNAP45 Variant Configuration 1 & 2 - Modeling and Integration PLM146 Variant Configuration 3 – Scenarios

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Mass Changes and the Product Structure Browser Lesson Duration: 20 Minutes

Lesson Overview In this lesson, we will discuss mass changes and the product structure browser in bills of material.

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

Update BOMs using mass changes Navigate the product structure browser

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

Business Example A component material is used on many BOMs and must be replaced. All the objects in a structure have to be displayed, processed, or created.

Mass Changes and the Product Structure Browser You can use the mass change function to make changes to items in several BOMs using only one function call.

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Figure 121: Mass Change in BOMs

The following item changes are supported for material items, document items, and class items: • • • •

Changing the component quantity Changing the item data Adding of items Replacing an item

•

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

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In all selected BOMs Using Engineering Change Management if necessary With restrictive selection criteria, such as plant and/or usage

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Figure 122: Product Structure

The product structure enables you to display and process all functionally related objects (such as material, BOM, document, and routing). The product data is displayed in a tree structure. You can restrict the display to only the detail data required for the current processing situation. You can explode the product structure across different systems. Data can be evaluated and processed either locally or in multiple systems (Application Link Enabling [ALE] destinations). You can: • • • • •

378

Go directly to display mode or processing mode for individual objects Display or process similar objects Create an additional tree structure for any object Select several objects for object management records in Engineering Change Management Jump to the engineering workbench

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Lesson: Mass Changes and the Product Structure Browser

Exercise 17: Mass Changes and the Product Structure Browser Exercise Duration: 10 Minutes

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

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

Task: Navigate the Product Structure Browser 1.

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

2.

Change item 0010 for BOM T-F## in plant 1000. Double the required quantity for component 0010.

3.

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

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Solution 17: Mass Changes and the Product Structure Browser Task: Navigate the Product Structure Browser 1.

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

Open the product structure browser Choose Cross-Application Components → Engineering Change Management → Environment → Product Structure or Logistics → Central Functions → Engineering → Engineering Change Management → Environment → Product Structure.

b)

Enter the material T-F## on the Material tab page and choose Enter .

c)

Expand the tree structures for bills of material and documents by clicking on the hierarchy node.

d)

Double-click on the symbols for bill of material or document to display the corresponding master record. You can also click on the eyeglasses to the right to display the documents.

e)

Select the individual objects then right-click to display a context menu. From the context menu, you can display or change objects or go to the engineering workbench.

f)

To recognize which T-F## components are also assemblies, we recommend placing the assemblies indicator in the layout. Select the right-hand side of the Change Layout button

2.

.

g)

Select the right-hand side of the Filter button and choose BOM item.

h)

Highlight the Assembly field and move to the left using the and then choose Enter.

i)

To display the BOM of an assembly, expand the appropriate node and right-click.

button

Change item 0010 for BOM T-F## in plant 1000.

Continued on next page

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Double the required quantity for component 0010.

3.

a)

Open the tree structure of BOM T-F## in plant 1000 at item level. Select the header of the BOM and right-click. Select Change.

b)

Double-click on the item number 0010.

c)

Change the required quantity.

d)

Choose Save.

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

Expand the hierarchy node Classification and select the Class.

b)

Right-click and select Characteristic Value Assignment or choose the Values icon .

c)

Pump height: 5 m (may vary) Pump capacity: 15 m3 (may vary) Usage: House technology (may vary)

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Lesson Summary You should now be able to: • Update BOMs using mass changes • Navigate the product structure browser

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Unit Summary

Unit Summary You should now be able to: • Explain the concept of a phantom BOM and when it should be used • Create a phantom BOM in SAP R/3 • Maintain phantom bills of material • Demonstrate model co-products and by-products • Demonstrate and explain the discontinuation process. • Model item substitutions in the bill of material • Discuss the advantages of using multiple and variant BOMs • Create a multiple BOM • Create a variant BOM • Define variant configuration • Update BOMs using mass changes • Navigate the product structure browser

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Unit Summary

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333

Test Your Knowledge

Test Your Knowledge 1.

A component with a negative quantity exists on a BOM. Select each of the following that it could be. Choose the correct answer(s).

□ □ □ □ 2.

A B C D

Co-product By-product Waste product Recursive product

Co-products, by-products, and waste products are materials on the BOM which you can choose to produce. Determine whether this statement is true or false.

□ □ 3.

True False

One of the differences between co-products, by-products, and waste products is their inventory valuation and settlement. Determine whether this statement is true or false.

□ □ 4.

True False

In order to use a material on a BOM as a co-product, you must first enable it to be used as a co-product in the material master. Determine whether this statement is true or false.

□ □

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True False

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Answers 1.

A component with a negative quantity exists on a BOM. Select each of the following that it could be. Answer: A, B, C A component on a BOM with a negative quantity could be a co-product, by-product, or a waste product.

2.

Co-products, by-products, and waste products are materials on the BOM which you can choose to produce. Answer: False Co-products, by-products, and waste products are materials on the BOM that are created simultaneously with the main product. The main product cannot be produced in isolation without producing these.

3.

One of the differences between co-products, by-products, and waste products is their inventory valuation and settlement. Answer: True Co-products have non-zero inventory valuation and are earmarked for cost settlement. By-products have a non-zero inventory valuation but are not earmarked for cost settlement. Waste products have zero inventory valuation and are not earmarked for cost settlement.

4.

In order to use a material on a BOM as a co-product, you must first enable it to be used as a co-product in the material master. Answer: True In order to use a material as a co-product on a BOM you must set the co-product indicator on the MRP 2 view of its material master record. In addition, you should also define the apportionment structure under the joint production button for cost settlement.

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Unit 9 Advanced Routing Functions

335

In this unit you will demonstrate to the participants advanced functions of the routing. It is important that participants understand that not all funcations may be used in their implementation.

Unit Overview This unit introduces several advanced concepts surrounding the use of routings in SAP ERP. Not all of the following functions will be required to use during the modeling of your company’s manufacturing process. These functions will include the user of parallel and alternative operations, detailed scheduling segments, scrap and other miscellaneous functions.

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

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Use parallel sequences in modeling complex manufacturing processes Use alternative sequences in modeling flexible manufacturing processes Model alternative manufacturing processes using alternative routings Use production versions to model a very specific production process Utilize reference operation sets to minimize routing maintenance Create a reference operation set Use a reference operation set in a routing Use a reference operation set as a template to create a routing Describe in detail the concept of lead time scheduling and updating in-house production time in the material master Identify the data used in lead time scheduling Explain how the SAP ERP system uses the data to determine the lead time schedule Update the material master record of a material from the routing Demonstrate the use of interoperation times in the routing for job shop related environments

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• • • • • • •

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Demonstrate the use of Overlapping for a continuous manufacturing process Demonstrate the use of splitting for multi-capacity work centers. Describe the use of trigger points to streamline and automate several administrative processes Explain how the assembly and component scrap in the material master field affect the production process Explain how the component scrap and operation scrap percentage in the bill of material affect the production process Explain how the scrap in the percentage field in the routing affects the production confirmation process Describe and use production resources/tools in the routing

Unit Contents Lesson: Modeling Complex and Flexible Manufacturing Processes .....389 Exercise 18: Creating Alternative and Parallel Sequences ...........393 Lesson: Modeling Alternative Manufacturing Processes ..................400 Exercise 19: Creating Alternative Routings and Production Versions......................................................................403 Lesson: Reference Operation Sets...........................................412 Exercise 20: Reference Operation Sets .................................415 Lesson: Lead Time Scheduling and Material Master Updates............423 Exercise 21: Scheduling...................................................427 Lesson: Time Components, Reduction Possibilities in the Routing ......432 Demonstration: Demonstrate how to Use Splitting in the Production Order .........................................................................436 Demonstration: Demonstrate the use of Continuous Flow............437 Exercise 22: Time Elements of the Operation in Scheduling .........441 Lesson: Trigger Points in the Routing........................................448 Demonstration: Setting Up a Trigger Point..............................450 Procedure: Setting Up a Trigger Point...................................452 Demonstration: Rework Operations and Orders During the Production Order Confirmation Process ..............................................452 Lesson: Scrap and Its Effects .................................................456 Demonstration: Assembly Scrap in Planned and Production Orders 458 Demonstration: Component Scrap in Planned and Production Orders ........................................................................459 Demonstration: Operation Scrap in Planned and Production Orders ........................................................................461 Exercise 23: Scrap in Production ........................................465 Lesson: Production Resources/Tools ........................................472 Demonstration: Assigning Material Components and Production Resources/Tools ............................................................474 Exercise 24: Creating and Assigning PRTs .............................475

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Lesson: 337

Lesson: Modeling Complex and Flexible Manufacturing Processes

Modeling Complex and Flexible Manufacturing Processes Lesson Duration: 20 Minutes

Lesson Overview In this lesson you will discuss the use of parallel and alternative sequences to model complex and flexible manufacturing processes.

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

Use parallel sequences in modeling complex manufacturing processes Use alternative sequences in modeling flexible manufacturing processes

Business Example Within the project team, you are responsible for routing management. You have several products that undergo complex manufacturing steps. Due to the unique nature of the process, several operations must occur simultaneously. In order to due this, you want to make use of parallel sequences in the routing. In addition, you have some machines that are identical in nature. For capacity planning purposes, you can switch jobs between the machines with little or no effect on the subsequent operations. You would like to use alternative sequences to model this flexible manufacturing opportunity.

Parallel Sequences You use a single sequence to represent a simple linear series of production steps in production. If you want to represent a more complex series of production steps, you link several sequences with relationships to predecessors and successors. In the simplest case a routing only has one sequence, the standard sequence. Every other sequence is either an alternative or a parallel sequence, depending on whether its operations are performed as an alternative to the standard sequence or in parallel (at the same time) with the standard sequence. Only routings can have alternative sequences, parallel sequences can be created in both routings and rate routings.

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Parallel sequences are special types of overlapping operations that can be used in various industries. A parallel sequence enables you to process several operations at the same time. It is carried out at the same time as the corresponding section in the standard sequence. It is a special form of overlapping operations. For example, in mechanical engineering for assembly lines with individual component manufacturing, a parallel sequence allows for several individual components from the BOM to be prepared as smaller units for final assembly. In the chemical industry, parallel sequences can be used to model analytical processes that occur parallel to the production process.

Figure 123: Sequence Scheduling

An alignment key defines the start of the individual parallel sequences and, consequently, the position of the sequence buffers. Only the first operation of a referenced operation set (or reference rate routing) that has not been unlocked can be used as a branch or as a return operation for alternative or parallel sequences. To use other operations within a reference operation set (or reference rate routing) for your parallel sequence, you must first unlock the reference. You can create parallel sequences in routings and rate routings. You cannot create them in reference operation sets or reference rate routings

Alternative Sequences in Routings A linear sequence of operations that is an alternative to a sequence of operations in the standard sequence.

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You use an alternative sequence for example, if: •

•

The production flow is different for certain lot-size ranges For instance you can machine a work piece on conventional machine or on NC machines. A NC machine has a longer set-up time than a conventional machine. However the machining costs are considerably less. Therefore whether you use NC machines will depend on the lot size. The production flow changes under certain business conditions. For instance, if you have a capacity problem, you have some production steps performed externally by a vendor.

You can enter a lot-size range, so that the system automatically selects the alternative sequence if an order lies within this range. The lot size range of an alternative sequence can differ from the one specified in the routing header. However, it must overlap at least partially with the lot size range in the routing header. Alternative sequences are linked to the standard sequence. Branch operations in the standard sequence are ignored in the procedure.

Figure 124: Alternative Sequences

Only the first operation of a referenced operation set that has not been unlocked can be used as a branch or as a return operation for alternative or parallel sequences. To use other operations within a reference operation set for your alternative sequence, you must first unlock the reference. You can only create alternative sequences in routings. You cannot create them in reference operation sets, reference rate routings or rate routings.

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341

Lesson: Modeling Complex and Flexible Manufacturing Processes

Exercise 18: Creating Alternative and Parallel Sequences Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create a parallel sequence • Allocate components to an operation in the parallel sequence

Business Example In your manufacturing process, you have steps in the process that are being done simultaneously. You would like to model this complex manufacturing process using parallel sequences.

Task: Create a routing with a parallel sequence for your finished material T-F## and allocate components to both the standard sequence and the parallel sequence. 1.

First, create the standard sequence of the routing for the production of material T-F## in plant 1000, which consists of the five steps in the table below. The routing should be creation status, valid from today’s date, for production usage, and for lot sizes from 1 to 100,000 pieces. Use the data in the table below to complete the routing information. Primary Operation Data: Operation #

Work Center

Control Key

Description

10

T-M##

PP01

Material staging by picking list

20

T-E##

PP01

Preassemble pump components

30

T-F##

PP01

Final assembly of pump

40

T-P##

PP99

Deliver to stock

Standard Processing Times:

Continued on next page

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2.

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Activity

Op 10

Op 20

Op 30

Op 40

Setup

0 Min

10 Min

15 Min

0 Min

Machine

0 Min

10 Min

10 Min

0 Min

Labor

10 Min

10 Min

10 Min

5 Min

Create the parallel sequence of the routing for the production of material T-F## in plant 1000, which consists of the three steps in the table below. Use the data in the table below to complete the routing information. Parallel Sequence Operation Data: Operation #

Work Center

Control Key

Description

10

T-V##

PP01

Cut sheet metal

20

T-V##

PP01

Drill and tap holes

30

T-L##

PP01

Cover and paint

Standard Processing Times:

3.

Activity

Op 10

Op 20

Op 30

Setup

10 Min

0 Min

15 Min

Machine

10 Min

0 Min

5 Min

Labor

0 Min

5 Min

5 Min

Assign material components from the BOM of T-F## to specific operations on the routing. Assign 100-700 to operation 10 of the parallel sequence and 100-600, 100-130, and the non-stock item to operation 30 of the standard sequence. Where will the other components that you haven’t assigned be allocated?

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Solution 18: Creating Alternative and Parallel Sequences Task: Create a routing with a parallel sequence for your finished material T-F## and allocate components to both the standard sequence and the parallel sequence. 1.

First, create the standard sequence of the routing for the production of material T-F## in plant 1000, which consists of the five steps in the table below. The routing should be creation status, valid from today’s date, for production usage, and for lot sizes from 1 to 100,000 pieces. Use the data in the table below to complete the routing information. Primary Operation Data: Operation #

Work Center

Control Key

Description

10

T-M##

PP01

Material staging by picking list

20

T-E##

PP01

Preassemble pump components

30

T-F##

PP01

Final assembly of pump

40

T-P##

PP99

Deliver to stock

Standard Processing Times:

Continued on next page

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2.

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Activity

Op 10

Op 20

Op 30

Op 40

Setup

0 Min

10 Min

15 Min

0 Min

Machine

0 Min

10 Min

10 Min

0 Min

Labor

10 Min

10 Min

10 Min

5 Min

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Create or use transaction code CA01.

b)

Enter the material T-F## and plant 1000 and choose Enter

c)

Enter usage 1 for production, status 1 for creation phase, planner group 0##, and lot size of 1 to 100,000 pieces.

d)

Choose the Operations Overview icon and enter the primary operation data from the table. Respond to any system messages that appear.

e)

Select all operations and choose Details → Operation from the menu. Enter the standard operation processing Times from the table and choose to navigate to the next operation detail screen. Continue to return to the until all times have been entered and then choose operation overview.

f)

Save your routing.

.

Create the parallel sequence of the routing for the production of material T-F## in plant 1000, which consists of the three steps in the table below. Use the data in the table below to complete the routing information. Parallel Sequence Operation Data: Operation #

Work Center

Control Key

Description

10

T-V##

PP01

Cut sheet metal

20

T-V##

PP01

Drill and tap holes

30

T-L##

PP01

Cover and paint

Standard Processing Times:

Continued on next page

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Activity

Op 10

Op 20

Op 30

Setup

10 Min

0 Min

15 Min

Machine

10 Min

0 Min

5 Min

Labor

0 Min

5 Min

5 Min

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter the material T-F## and plant 1000 and choose Enter

c)

Choose the Sequence Overview icon. Notice only the standard sequence is listed and this one is always numbered 0.

d)

Choose the Create icon

e)

Accept the default sequence number, enter Cut and paint sheet metal as the description, select the alignment key Align with latest dates, and enter reference sequence 0 and return operation 20.

f)

Choose the Operations Overview icon and enter the parallel sequence operation data from the table. Respond to any system messages that appear with No.

g)

Select all operations and choose Details → Operation from the menu. Enter the standard operation processing times from the table and to navigate to the next operation detail screen. Continue choose until all times have been entered and then choose to return to the operation overview.

h)

Choose the Sequence Overview icon again. Notice there are now two sequences: the standard sequence number 0 and the parallel sequence number 1.

i)

Select both sequences by clicking the button to the left of each and

and select Parallel sequence.

choose the Operation Graphic icon

3.

.

j)

Choose the Expand All icon routing.

k)

Choose

.

to view the graphic details of your

to return to the sequence overview and save your routing.

Assign material components from the BOM of T-F## to specific operations on the routing. Assign 100-700 to operation 10 of the parallel sequence and 100-600, 100-130, and the non-stock item to operation 30 of the standard sequence.

Continued on next page

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Where will the other components that you haven’t assigned be allocated?

398

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

Chose the Component Allocation icon on the tool bar and select the alternative 1 Bill of Material.

d)

Select items 100-700 from the BOM that appears. Choose the New Assignment icon on the tool bar .

e)

You can enter sequence 1 operation 10 in the Activity field or choose Oper./act. list icon to select the operation from a list.

f)

Choose Continue and repeat steps d) through e) for components 100-300, 100-130, and the non-stock item, assigning them to operation 30 of sequence 0.

g)

Choose Save

h)

All other components that have not been assigned to any operation will default to the first operation of the standard sequence.

.

to save your routing and exit.

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Lesson: Modeling Complex and Flexible Manufacturing Processes

Lesson Summary You should now be able to: • Use parallel sequences in modeling complex manufacturing processes • Use alternative sequences in modeling flexible manufacturing processes

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Modeling Alternative Manufacturing Processes Lesson Duration: 20 Minutes

Lesson Overview In this lesson we will discuss the use of alternate routings to model alternative manufacturing processes. You will also learn about the use of production versions.

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

Model alternative manufacturing processes using alternative routings Use production versions to model a very specific production process

Business Example Within the project team, you are responsible for routing management. Several of your products require specific production cycles that are lot-size dependent. To model this in SAP ERP, you must create routing alternatives for these products.

Alternative Routings Different production lot sizes may require alternative production methods for reasons of efficiency.

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Figure 125: Routings

The same material can be produced with different routings. The different routings can be from different plants. A single product with one BOM can be manufactured using different technologies. You might use an automatic assembly line for large quantities and a manual assembly line for small quantities. The end result, however, is the same material for both assembly lines. A product can be made of different combinations of components, depending on the quantity (lot size) to be manufactured. This type of product is represented by alternative BOMs. A product can have up to 1000 alternative BOMs that only differ slightly, usually in terms of the component quantity. In the above example, a single product is manufactured using different manufacturing technologies, which require different bills of material. This necessitates not only different routings, but also different BOMs. Machine 1 represents the older technology where the product is assembled from two previously assembled components. Machine 2 is a newer piece of equipment supporting the assembly of the product from four raw materials. Each routing requires a BOM for the product representing the unique components consumed by each manufacturing process. The selection of alternatives is controlled by the material master record and could be based on lot size, date, or production version.

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Production Versions In the example illustrated below, a product is manufactured using two sets of technologies and methods. This necessitates different routings and different BOMs.

Figure 126: Production Versions

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.

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Exercise 19: Creating Alternative Routings and Production Versions Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create an alternative routing • Create a routing using the Engineering WorkBench

Business Example You have two different ways of manufacturing your product, T-B##. You need another routing to model the manufacturing options. Your company is considering using the Engineering Workbench for master data maintenance. You will use the EWB to create another routing for your material.

Task 1: Use the EWB to create a second routing to model an alternate manufacturing process. This manufacturing process is only to be used for small lot sizes. 1.

Access the EWB using the P_ALLES working area and load the existing task list for T-B##.

2.

Create a second routing for the production of material T-B## in plant 1000, which consists of the five steps in the table below. The routing should be creation status, valid from today’s date, for production usage, and for lot sizes from 1 to 100 pieces. Use the data in the table below to complete the routing information. Primary Operation Data: Operation #

Work Center

Control Key

Description

10

1112

PP01

Lathe casing

20

1114

PP01

Drill holes

30

1310

PP01

Preassembly

40

1310

PP01

Final assembly

50

1310

PP01

Deliver to stock

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Activity

Op 10

Op 20

Op 30

Op 40

Op 50

Setup

10 Min

10 Min

0 Min

0 Min

0 Min

Machine

30 Min

10 Min

0 Min

0 Min

0 Min

Labor

30 Min

10 Min

5 Min

5 Min

10 Min

Now maintain the header information for your task lists for material T-B##.

Task 2: Assign components to operations on your alternate routing. Change the lot size so one routing is valid for small lot sizes 1-10 and the other is valid for large lot sizes 11-100,000. Be sure to release both routings for production. 1.

Assign component T-T2## to operation 30 and component T-T3## to operation 40 on your new routing with group counter 2.

2.

Change the lot size on routing with group counter 1 so it is valid for lot sizes 11-100,000 and set the status to Released (general) for both routings.

Task 3: Display your routing using the SAP transactions and answer the following questions. 1.

Display your routing.

2.

What are the group number and group counter? How does this compare with the other routing for T-B## with Group Counter 1?

Task 4: Create production versions for the selection of routings.

404

1.

Create a production version 0001 for the selection of BOMs and routings for T-B##. The production version should be valid from today until 12/31/9999, for lot sizes 11 to 100,000 pc. Use task list type routing with your routing for T-B## group counter 1, and use BOM alternative 1 with usage 1.

2.

Create another production version 0002 for the selection of BOMs and routings for T-B##. The production version should be valid from today until 12/31/9999, for lot sizes 1 to 10 pc. Use task list type routing with your routing for T-B## group counter 2, and use BOM alternative 1 with usage 1.

3.

For the system to select your routings by production versions for this material, you will need to change the Selection Method field on the MRP4 view of the material master.

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Solution 19: Creating Alternative Routings and Production Versions Task 1: Use the EWB to create a second routing to model an alternate manufacturing process. This manufacturing process is only to be used for small lot sizes. 1.

2.

Access the EWB using the P_ALLES working area and load the existing task list for T-B##. a)

Choose Logistics → Production → Master Data → Engineering Workbench or use transaction code CEWB.

b)

Select the P_ALLES working area and choose Continue.

c)

Enter material T-B## and plant 1000 in the Basic Selection Criteria section.

d)

Choose Load Task Lists and BOMs .

e)

In the Headers Overview you now see a list of task lists for your selection criteria.

Create a second routing for the production of material T-B## in plant 1000, which consists of the five steps in the table below. The routing should be creation status, valid from today’s date, for production usage, and for lot sizes from 1 to 100 pieces. Use the data in the table below to complete the routing information. Primary Operation Data: Operation #

Work Center

Control Key

Description

10

1112

PP01

Lathe casing

20

1114

PP01

Drill holes

30

1310

PP01

Preassembly

40

1310

PP01

Final assembly

50

1310

PP01

Deliver to stock

Standard Processing Times:

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Activity

Op 10

Op 20

Op 30

Op 40

Op 50

Setup

10 Min

10 Min

0 Min

0 Min

0 Min

Machine

30 Min

10 Min

0 Min

0 Min

0 Min

Labor

30 Min

10 Min

5 Min

5 Min

10 Min

a)

In the EWB, select the

Create icon.

b)

In the second row of the table (headers), enter 2 for the Group Counter and lot size 1 to 99,999,999 and choose Enter .

c)

A lock will appear on that second row. Now select that row and choose Task LIsts → Operations.

d)

In the first row of the table (operations), enter the work center for operation 10 from the above Primary Operation Data table and choose Enter. Respond to any dialog boxes that appear by choosing Enter .

e)

Enter or replace the Operation Short Text with the text listed in the above table.

f)

Continue this process with the next row in the table until all 5 operations in the Primary Operation Data have been entered.

g)

Select the Processing Times tab and enter the data from the Standard Save. Processing Times table above and save your data by choosing

Now maintain the header information for your task lists for material T-B##. a)

In the EWB, choose the menu path Task Lists → Headers.

b)

In the table for the header of Group Counter 2 change the lot size validity to 1 to 10.

c)

Scroll to the right in the table and enter 0## in the Planner Group field and save.

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Task 2: Assign components to operations on your alternate routing. Change the lot size so one routing is valid for small lot sizes 1-10 and the other is valid for large lot sizes 11-100,000. Be sure to release both routings for production. 1.

2.

Assign component T-T2## to operation 30 and component T-T3## to operation 40 on your new routing with group counter 2. a)

In the EWB, use the menu path Task Lists → Component Assignments and enter PP01 for the application if the dialog box appears.

b)

In the row for item T-T2## from the BOM that appears, enter 30 in the operation field in the table.

c)

In the row for item T-T3## from the BOM that appears, enter 40 in the operation field in the table.

d)

Choose Save

to save your routing.

Change the lot size on routing with group counter 1 so it is valid for lot sizes 11-100,000 and set the status to Released (general) for both routings. a)

In the EWB, use the menu path Task Lists → Headers

b)

On the Headers General tab, select the header with group counter Change. 1 and choose

c)

Change the lot size validity fields to 11 to 100,000.

d)

Scroll to the right and change the status to 4 Released (general) for both routings.

e)

Choose Save

to save your routings and exit.

Task 3: Display your routing using the SAP transactions and answer the following questions. 1.

Display your routing. a)

From the main menu choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03.

b)

Enter T-B## and plant 1000 and choose

c)

On the Routing overview screen, select the routing with group counter 2 and choose .

.

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What are the group number and group counter? How does this compare with the other routing for T-B## with Group Counter 1? a)

The group number will vary but should be a number beginning with 50000____ and the group counter should be 2.

b)

The group number is the same as the group number for the other routing for T-B## but the group counter is different.

Task 4: Create production versions for the selection of routings. 1.

Create a production version 0001 for the selection of BOMs and routings for T-B##. The production version should be valid from today until 12/31/9999, for lot sizes 11 to 100,000 pc. Use task list type routing with your routing for T-B## group counter 1, and use BOM alternative 1 with usage 1. a)

Choose Logistics → Production → Master Data → Production Versions or use transaction code C223.

b)

Delete all entries in the Selection condition fields except Material T-B## and Plant 1000. Then choose Enter .

c)

You should now be able to enter the data for material T-B##, production version 0001, and text Normal Production. By hitting ENTER twice to work through the warning, the valid dates will default.

d)

You can continue to work in the table or you can double-click on the production version number 0001 and work in the detail screen to enter data, which might make data entry easier.

e)

Enter lot size 11 to 100,000 pc.

f)

In the Task List section, choose Routing from the list for Task List Type.

g)

Enter your routing’s group number in the Group field. If you don’t know the group number, you can find the correct routing by using the F4 search function or the drop-down list. Choose tab C: Search using material and choose Continue . Be sure to choose the routing with group counter 1.

h)

In the Bill of Material section, enter alternative BOM 1 and usage 1.

i)

Now you can close the detail screen by choosing

.

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2.

Create another production version 0002 for the selection of BOMs and routings for T-B##. The production version should be valid from today until 12/31/9999, for lot sizes 1 to 10 pc. Use task list type routing with your routing for T-B## group counter 2, and use BOM alternative 1 with usage 1. a)

Choose Logistics → Production → Master Data → Production Versions or use transaction code C223.

b)

Delete all entries in the Selection condition fields except Material T-B## and Plant 1000. Then choose Enter .

c)

Now you should be able to enter the data for material T-B##, production version 0002, and text Small Lot Size Production. By hitting ENTER twice to work through the warning, the valid dates will default.

d)

You can continue to work in the table, or you can double-click on the production version number 0002 and work in the detail screen to enter data, which might make data entry easier.

e)

Enter lot size 1 to 10 pc.

f)

In the Task List section, choose Routing from the list for Task List Type.

g)

Enter your routing’s group number in the Group field. If you don’t know the group number, you can find the correct routing by using the F4 search function or the drop-down list. Choose tab C: Search using material and choose Continue . Be sure to choose the routing with group counter 2.

h)

In the Bill of Materiall section, enter alternative BOM 1 and usage 1.

i)

Now you can close the detail screen by choosing

j)

Be sure to save your production versions.

.

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For the system to select your routings by production versions for this material, you will need to change the Selection Method field on the MRP4 view of the material master. a)

Choose Logistics → Production → Master Data → Material Master → Material → Change → Immediately or use transaction code MM02.

b)

Enter material T-B## and press ENTER.

c)

Select the MRP 4 view from the list and press ENTER.

d)

Enter plant 1000 and press ENTER.

e)

In the BOM explosion/dependent requirements section, change the Selection Method field to 2 Selection by production version or 3 Selection only by production version.

f)

Choose Save. Now the system will use the production versions for selection of the BOM and routing for this material.

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Lesson: Modeling Alternative Manufacturing Processes

Lesson Summary You should now be able to: • Model alternative manufacturing processes using alternative routings • Use production versions to model a very specific production process

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Reference Operation Sets Lesson Duration: 20 Minutes

Lesson Overview In this lesson you will learn about reference operation sets and how to use them. You will create a reference operation set and reference it in your routing. You will also use a reference operation set as a template for creating routings.

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

Utilize reference operation sets to minimize routing maintenance Create a reference operation set Use a reference operation set in a routing Use a reference operation set as a template to create a routing

Discuss reference operation sets as building blocks for routings.

Business Example The inspection process for several different pumps consists of the same steps. You need an efficient way to maintain these steps on multiple routings. Your group routing uses the same steps, but they have different standard values. You want to use these inspection steps as a template as an efficient way of creating your group routing.

Reference Operation Sets A reference operation set is a standard operation sequence for performing a task that is frequently used. Creating a reference operation set provides an efficient way to maintain this set of operations. It can be used either as a reference or as a template when you create a routing.

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Figure 127: Reference Operation Sets

The reference to a reference operation set is created in the operation overview. The operations in the reference operation set are renumbered to fit into the routing. A reference operation set does not allow parallel or alternative sequences. Material components, PRTs, and trigger points can be assigned to an operation in a reference operation set. Any assignments to a reference operation set will be copied into the routing. Any change made to a reference operation set will update all routings that use it. A reference operation set can be created manually, or a routing or reference operation set can be used as a template. If you copy from a routing, only the basic sequence is copied. If you copy from a reference operation set, there is no reference.

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Exercise 20: Reference Operation Sets Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create a reference operation set • Use a reference operation set in a routing • Use a reference operation set as a template to build a routing

Business Example In your production process, there is an inspection process that is common to many routings. Since the steps and standard values are identical for all routings, you need an efficient way to maintain this data. In your group routing, the steps are identical but the standard values are different. You need an efficient way to build these steps into your routing but still be able to change the standard times.

Task 1: Create a reference operation set for the inspection of manufacturing products. 1.

Create a reference operation set for the inspection of your manufacturing products. This will be an in-process inspection to be used for production with status Release (general). Assign it to your planner group 0##, use the description In-process inspection ##, and enter the data in the table below. Operation

Work Center

Control Key

Description

Labor

10

R-K##

PP01

Test Inspection

10 Min

20

R-P##

PP01

Examine after testing

5 Min

Task 2: Assign the reference operation set to your routing. 1.

Change your routing for T-F## to include the reference operation set you just created. This inspection needs to take place just prior to final assembly, and again before delivery to stock.

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Task 3: Use your reference operation set to build inspection steps into your group routing. 1.

Your group routing PUMP## also needs the same inspection steps, but since the standard values are different in this routing you will use the reference operation set to insert the operations and then unlock the reference so you can change the standard values for this routing. The reference operation set should be inserted at operations 35 and 45. Only unlock the reference at 35, since those are the only standard values that are different.

Task 4: New inspection requirements have increased the standard time at inspection work center R-K## from 10 min to 15 min. Change your reference operation set to reflect this new time.

416

1.

Change the standard value of operation 10 in your reference operation set from 10 min to 15 min and update all routings to which it is assigned. What does the warning message mean?

2.

Display your routing for T-F## and plant 1000 to make sure the changes were made.

3.

Display your group routing PUMP## to check if the changes have also been made there. Was the standard value for operation 45 changed? Was the standard value for operation 35 changed? Why or why not?

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Solution 20: Reference Operation Sets Task 1: Create a reference operation set for the inspection of manufacturing products. 1.

Create a reference operation set for the inspection of your manufacturing products. This will be an in-process inspection to be used for production with status Release (general). Assign it to your planner group 0##, use the description In-process inspection ##, and enter the data in the table below. Operation

Work Center

Control Key

Description

Labor

10

R-K##

PP01

Test Inspection

10 Min

20

R-P##

PP01

Examine after testing

5 Min

a)

Choose Logistics → Production → Master Data → Routings → Routings → Reference Operation Sets → Create or use transaction code CA11.

b)

Choose Enter

c)

Enter the description In-process inspection ##, usage 1, status 4, planner group 0##, lot size 1 to 100000 pc, and choose the Operation overview icon.

d)

Enter the data from the table and save. Make note of the system assigned group number that appears in the status bar when you save.

without entering any data in the initial screen.

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Task 2: Assign the reference operation set to your routing. 1.

Change your routing for T-F## to include the reference operation set you just created. This inspection needs to take place just prior to final assembly, and again before delivery to stock. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the operation overview, choose Extras → Reference → Create.

d)

Enter operation 25 and the group number of the reference operation set you recorded earlier. If you don’t have the group number, you can search possible entries with the drop-down list. Choose S: Reference operation sets and enter your planner number 0##. Then choose Enter and your reference operation set will appear on a list for you to choose it.

e)

Repeat step d for operation 35.

.

Note: Notice the operations of the reference operation set are display only and cannot be changed here. Changes will need to be made in the reference operation set. All routings to which it is assigned will then be automatically updated.

Task 3: Use your reference operation set to build inspection steps into your group routing. 1.

Your group routing PUMP## also needs the same inspection steps, but since the standard values are different in this routing you will use the reference operation set to insert the operations and then unlock the reference so you

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can change the standard values for this routing. The reference operation set should be inserted at operations 35 and 45. Only unlock the reference at 35, since those are the only standard values that are different. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Be sure the material number is blank, enter plant 1000, group PUMP##, and choose Enter .

c)

From the operation overview, choose Extras → Reference → Create.

d)

Enter operation 35 and the group number of the reference operation set you recorded earlier. If you don’t have the group number, you can search possible entries with the drop-down list. Choose S: Reference operation sets and enter your planner number 0##. Then choose Enter and your reference operation set will appear on a list for you to select it.

e)

Repeat step d using operation 45.

f)

Select operation 35 and choose Extras → Reference → Unlock.

g)

Now change the standard times of operations 35 and 36 to 5 Min and 3 Min, respectively. Note: Be aware that since this reference has been unlocked, any changes to the reference operation set will not update operations 35 and 36.

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Task 4: New inspection requirements have increased the standard time at inspection work center R-K## from 10 min to 15 min. Change your reference operation set to reflect this new time. 1.

2.

Change the standard value of operation 10 in your reference operation set from 10 min to 15 min and update all routings to which it is assigned. What does the warning message mean? a)

Choose Logistics → Production → Master Data → Routings → Routings → Reference Operation Sets → Change or use transaction code CA12.

b)

Enter the group number of your reference operation set or search for it as previously indicated and choose Enter .

c)

Acknowledge the warning message that appears. This message means that upon saving, any changes made to the reference operation set will update all routings to which it is assigned.

d)

Double-click on operation number 10 to go to the details of the operation. Change the 10 Min of labor time to 15 Min.

e)

Save the reference operation set.

Display your routing for T-F## and plant 1000 to make sure the changes were made. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

Double-click on operation number 25 and check the details to be sure the labor time is now 15 Min.

d)

Repeat this for operation number 35.

.

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3.

2010

Display your group routing PUMP## to check if the changes have also been made there. Was the standard value for operation 45 changed? Was the standard value for operation 35 changed? Why or why not? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03.

b)

Be sure the material number is blank, enter plant 1000, group PUMP##, and choose Enter .

c)

Double-click on operation number 45 and check the details to be sure the labor time is now 15 Min. Yes, this standard value was changed when the reference operation set was saved.

d)

Repeat this for operation number 35. No, the standard values here were not changed because the link back to the reference operation set was broken when it was unlocked.

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Lesson Summary You should now be able to: • Utilize reference operation sets to minimize routing maintenance • Create a reference operation set • Use a reference operation set in a routing • Use a reference operation set as a template to create a routing

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Lesson: 371

Lesson: Lead Time Scheduling and Material Master Updates

Lead Time Scheduling and Material Master Updates Lesson Duration: 30 Minutes

Lesson Overview This lesson describes the details of lead time scheduling and updating in-house production time in the material master.

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

Describe in detail the concept of lead time scheduling and updating in-house production time in the material master Identify the data used in lead time scheduling Explain how the SAP ERP system uses the data to determine the lead time schedule Update the material master record of a material from the routing

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

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 either the lot-size-independent or lot-size-dependent in-house production time for internally procured materials, or the planned delivery time for externally procured

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materials. The in-house production time for a material can be calculated using lead time scheduling of a routing without an order, and can then copied to the material master.

Figure 128: Calculation of Basic Dates

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

Figure 129: Scheduling in Production Planning

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

Figure 130: Scheduling 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.

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Exercise 21: Scheduling Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Schedule a routing • Analyze the schedule of a routing using a table and Gantt chart • Update the basic dates in the material master from the schedule of the routing

Business Example It is important to ensure that the production schedule is accurate. Therefore, you need to analyze the scheduling of routings before they are used to create production order. In addition, to ensure that basic date and lead time scheduling are synchronized, you will need to schedule the routing and update the material master record.

Task 1: Schedule your routing to make sure the production schedule is accurate. Display the schedule using an object overview and a Gantt chart. 1.

Schedule your routing for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule.

Task 2: Schedule your routing and update the material master record with the schedule data.

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1.

Schedule your routing for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and update the material master record.

2.

Update the material master record with the schedule data.

3.

Now check the material master to be sure it was updated.

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Solution 21: Scheduling Task 1: Schedule your routing to make sure the production schedule is accurate. Display the schedule using an object overview and a Gantt chart. 1.

Schedule your routing for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today’s date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

Make sure all your operations are scheduling correctly in the scheduling overview table that appears. Make any necessary corrections and schedule the routing again.

g)

Click the Gantt chart icon

.

and view the schedule graphically.

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Task 2: Schedule your routing and update the material master record with the schedule data. 1.

2.

Schedule your routing for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and update the material master record. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today’s date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

In the Scheduling Overview, select the Scheduling Results icon.

g)

In the dialog box that appears, you can compare the scheduling results with the current material master settings. Choose the Update mat. master button in the dialog box.

h)

You should receive a message box that says “Scheduling data marked for material master update.”

.

Update the material master record with the schedule data. a)

Choose Logistics → Production → Master Data → Routings → Extras → Material Master → Update Material Master or use transaction code CA96.

b)

Enter plant 1000, production planner 0##, and choose Enter

c)

Select your material from the list and choose the Update mat. master icon on the tool bar.

.

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Now check the material master to be sure it was updated. a)

Choose Logistics → Production → Master Data → Material Master → Material → Display → Display Current or use transaction code MM03.

b)

Enter material T-F## and choose Enter

c)

Select the Work Scheduling view and choose

d)

Enter plant 1000 and choose

e)

You should see the results of the update in the In-house production time in days section.

. .

.

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Lesson: Lead Time Scheduling and Material Master Updates

Lesson Summary You should now be able to: • Describe in detail the concept of lead time scheduling and updating in-house production time in the material master • Identify the data used in lead time scheduling • Explain how the SAP ERP system uses the data to determine the lead time schedule • Update the material master record of a material from the routing

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Time Components, Reduction Possibilities in the Routing Lesson Duration: 30 Minutes

Lesson Overview In this lesson you will look at the various options for detailed scheduling including interoperations times, continuous input/ouput, and splitting operations in multiple capacity work centers.

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

Demonstrate the use of interoperation times in the routing for job shop related environments Demonstrate the use of Overlapping for a continuous manufacturing process Demonstrate the use of splitting for multi-capacity work centers.

Business Example As a member of the project team, you are responsible for the precise time scheduling of your products. In order to do this you need to model the critical path and any possible interoperation or float time that might occur during a normal production. To ensure this can happen, you need to review the use of interoperation times, overlapping, and splitting in the routing operations.

Modeling Standard Float Time in the Routing Since malfunctions and other disturbances in the production process can never be fully prevented, the system carries out scheduling using a float before and a float after production. The floats before and after production are defined in the material master record using a scheduling margin key. The two float times serve different purposes:

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Float before production The float before production has the following two functions in the order: It can compensate for delays in the staging of the material components or if there is a capacity bottleneck at the work centers involved, you can move the production dates forward in the future. In this way it serves as a float for capacity leveling. The system calculates the scheduled start by adding the float before production to the basic start date. Float after production The float after production is used in the order to compensate for unexpected interruptions in the production process. It prevents a delay of the scheduled finish. The system calculates the scheduled finish by subtracting the float after production from the basic finish date.

Figure 131: Time Elements in Lead Time Scheduling

The order float can be predefined and is controlled by the scheduling margin key. In Customizing, the scheduling margin key is defined and then assigned on the MRP 2 view of the material master record. The duration of an operation consists of a maximum of five time components: • • • • •

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

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Queue Time In addition to the floats before and after production, you can define an operation float in the form of a queue time. The queue time is used to compensate for malfunctions and delays within an operation. The queue time is the interval between the earliest and latest dates of the operation (see the following figure). During each scheduling run, the system calculates the earliest and the latest dates for the individual operation segments. You can maintain the queue time in both the work center and operation. However, the system only schedules with the queue time in the work center if you have not maintained the queue time in the operation. If the lead time of an operation must be reduced, the system can shorten the standard queue time as far as the minimum queue time. Setup Time The setup time is the time needed to prepare the work center for operations to perform there. The setup time is part of the lead-time. Processing Time The processing time is the time needed to process a material in an operation. The processing time is dependent on the order quantity, and does not contain a setup or teardown time. It is part of the execution time. Teardown Time The teardown time is the time needed to restore a work center to its normal state after operations have been processed. The teardown time is part of the execution time. Wait Time The wait time is the time between the end of the execution time and the start of move time. In the SAP system, types of wait time are: • •

Maximum Minimum

In scheduling, only the minimum wait time is taken into account. The maximum wait time is used for information. Using the teardown/wait simul. indicator in the interoperation times section of the Operation Details screen, you can specify whether teardown and wait are to be considered as simultaneous or consecutive operation segments in scheduling. If teardown and wait times are simultaneous, the lead time of the operation is reduced The wait time is scheduled without taking the factory calendar into account. This means that it can be scheduled daily from 0.00 to 24.00. Move Time

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In addition to these operation segments, you can define a move time. The move time is the time needed to move a material from one work center to the next one. Move time is always between two operations and is assigned to the preceding operation. You can maintain the move time in the individual operations or in Customizing per location group in the move time matrix. In the interoperation times section of the Operation Details screen, you can maintain a minimum and a standard move time. If reduction measures are carried out, the system schedules the operations using the minimum move time. The system determines the move time using the move time matrix, only if you do not maintain move times in the interoperation times section of the Operation Details screen. You can combine work centers which are in close proximity to each other into location groups. You can define location groups in Customizing and assign a work center to a location group on the Scheduling screen of the work center. In the move time matrix, you can specify planned values for the move time within a location group or from one location group to another. For each entry, you can specify a minimum and a standard move time. The operation segments and the move time are used to determine the execution time, lead time and interoperation time of an operation. 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 depending on the customizing settings. For external operations, the delivery time is specified in days. These operations are scheduled based on the Gregorian calendar.

Figure 132: Time Components and Their Origins

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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

Modeling Operation Splits in the Routing An operation is split if it is carried out on several machines or by several persons at the same time. Splitting an operation has the following effects on the operation dates: The processing time/execution time becomes shorter. Setup and teardown must be carried out more than once for the operation.

Demonstration: Demonstrate how to Use Splitting in the Production Order Purpose

System Data System: T34 Client: 800 User ID: Password: Set up instructions: No setup required. 1. Use Tcode CA02 and schedule your routing for T-F## with lot size 100 and operation segments variant. Show the results of operation 20 is 1000 min.

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2.

Now change operation 20 to force a split. In the operations details and the splitting section, check the splitting required indicator. You don’t need to specify the number of splits, it will default to the number of capacities in the work center.

3.

Now schedule the routing again and show that operation 20 now schedules for 333.3 min because it is split across 3 machine capacities.

4.

Show the results and the total lead time of the order is reduced to 21 days.

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Modeling Continuous Manufacturing as with Multiple Operations To reduce the lead time of a routing or production order you can overlap operations. This means that an operation starts before the previous operation has finished You can define for each individual operation whether it should overlap with the next consecutive operation and in what way. To do this you can set the following indicators: •

Required overlapping This means the operations always overlap

•

Optional overlapping This means the operations overlap if scheduling uses a reduction level that allows overlapping

•

Flow manufacturing This means the system extends the lead time of all operations, that overlap using flow manufacturing, to the same length as the lead time of the longest of these operations. As with required overlapping, the operations always overlap

For every type of overlapping you can • •

Define a minimum overlap time which only allows overlapping after a particular minimum limit has been reached. Define a minimum send-ahead quantity to ensure that the operation is performed for a particular minimum quantity of the material to be produced, before the next operation starts.

Demonstration: Demonstrate the use of Continuous Flow Purpose Show the effect of continuous flow on the lead time of the routing. The routing is currently scheduling the production of all 100 pieces at operation 10 before passing the entire quantity to operation 20, etc. Here overlap the operations with a send ahead quantity of 1. Show the scheduling times of the operations hasn’t changed, the results show the total lead time reduced, and the Gantt chart shows how the operations now overlap.

System Data System: Client:

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User ID: Password: Set up instructions: No setup required. 1. If you have just shown the previous demo then just remind students that the lead time of the routing is 21 days. If not, then schedule your T-F## routing with a lot size of 100 to show them it schedules for 22 days without splitting or 21 days with splitting. 2.

Now change each operations in the routing to overlap with the send ahead quantity of 1. Do this in the operation details, Overlapping section by selecting the required overlapping indicator and entering the send ahead quantity of 1 in the appropriate field. Be sure to point out that the operations from the reference operation set cannot be changed here.

3.

Now schedule the routing again with a lot size of 100. show each operation still schedules the same time. Show the results now schedules 17 days total lead time. Show the Gantt chart and how the operations now overlap.

Reduction Measures The system can carry out reduction measures in lead time scheduling for orders. If the lead time calculated in scheduling is longer than the time between the basic dates, the system will carry out reduction measures to reduce the lead time. Reduction is carried out step by step. After each reduction measure, the system checks whether the calculated dates are within the basic dates. If this is the case, no further reduction measures are carried out.

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Figure 133: Reduction Process in Scheduling Routings

You can assign a reduction strategy to each operation in the interoperation times section of the Operation Details screen. This strategy specifies how many reduction levels may be applied to an operation (maximum of six levels) which reduction measures are carried out at the individual levels. The order is rescheduled after every reduction level. To improve performance it is recommended that you keep the number of reduction steps to a minimum.

Figure 134: Reduction Strategy

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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). The following reduction measures can be carried out with respect to the operation: Reduction of the queue time: •

• • • •

For each reduction level, you can specify the percentage by which the queue time is to be reduced. However, you cannot reduce to a value smaller than the minimum queue time. Reduction of the execution time by splitting - Dividing an operation between several people or machines results in a reduction of the execution time. Reduction of the lead time by overlapping - You can reduce the overall lead time of an order by overlapping operation processing. Reduction of the move time - You can reduce the standard move time as far as the minimum move time. The minimum wait time cannot be reduced.

You can also specify reduction for the floats before and after production in the order or in Customizing for each plant, order type and planner group. In order to reduce the lead time of a routing with parallel sequences, you specify that reduction is only carried out on operations, if a reduction in their execution time leads to a reduction in the overall lead time of the order. The sequence of such operations in the routing with parallel sequences forms the "critical path". If applying reduction measures to an operation, would not lead to an overall lead time reduction, this operation is not reduced. If a routing does not contain parallel sequences, there is no critical path. All operations are then reduced, irrespective of whether you have selected reduction via the critical path or not.

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Exercise 22: Time Elements of the Operation in Scheduling Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create an operation in a routing that splits the workload over several machines • Create operations that model continuous output and overlap the previous operation to reduce lead time

Business Example One operation in your routing to produce pumps has several machines that can do the work. You need to be sure the routing will schedule the workload across all machines. As part of a lean manufacturing initiative at your company, you are required to perform single-piece production.

Task 1: Change the operation on your routing to require splitting the workload across all machines. 1.

Schedule your routing for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

2.

Operation 20 in your routing, preassembly of the pump, has a work center with three machines (three individual capacities). Change this operation to require splitting across all three machines.

3.

Schedule your routing again for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. Compare the differences in scheduling. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

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Task 2: Due to a lean manufacturing initiative in your company, you are required to use single-piece manufacturing. Change your routing to accommodate this requirement.

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1.

Change your routing so every operation requires overlapping with one piece send-ahead quantity.

2.

Schedule your routing again for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. Compare the differences in scheduling. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days?

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Solution 22: Time Elements of the Operation in Scheduling Task 1: Change the operation on your routing to require splitting the workload across all machines. 1.

2.

Schedule your routing for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today’s date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

The processing time (labeled Edit) for operation 20 is 1000 min.

g)

In the Scheduling Overview, select the Scheduling Results icon. Make note of the lead time in days for the entire routing.

h)

Click the Gantt chart icon

.

and view the schedule graphically.

Operation 20 in your routing, preassembly of the pump, has a work center with three machines (three individual capacities). Change this operation to require splitting across all three machines. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

Double-click on operation number 20 to go to the details of the operation.

d)

Scroll down to the splitting section and select the indicator for Required splitting. You need not enter the number of splits, but let it default to the number of individual capacities.

.

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3.

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Schedule your routing again for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. Compare the differences in scheduling. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today’s date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

The processing time (labeled Edit) for operation 20 is 333.3 min.

g)

In the Scheduling Overview, select the Scheduling Results icon. Make note of the lead time in days for the entire routing.

h)

Click the Gantt chart icon

.

and view the schedule graphically.

Continued on next page

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Task 2: Due to a lean manufacturing initiative in your company, you are required to use single-piece manufacturing. Change your routing to accommodate this requirement. 1.

Change your routing so every operation requires overlapping with one piece send-ahead quantity. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

Select all operations and choose Details → Operations to go to the details of the operation.

d)

Scroll down to the overlapping section, select Required overlapping, and enter 1 pc in the min. send-ahead qty.

e)

to go to the next operation and repeat the settings until all Choose operations have been performed.

f)

Click the green back arrow to get back to the operations overview and then choose the Sequence overview icon to see the other sequences.

g)

Select sequence 1, the parallel sequence, and choose the Operations overview icon .

h)

Select all operations and choose Details → Operations to go to the details of the operation.

i)

Scroll down to the overlapping section, select Required overlapping, and enter 1 pc in the min. send-ahead qty.

j)

Choose to go to the next operation and repeat the settings until all operations have been performed.

k)

Save your changes.

.

Continued on next page

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2.

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Schedule your routing again for the pump T-F## using forward scheduling from today’s date with a lot size of 100 pc. Use the operation segments overview variant and the Gantt chart to view your schedule. Compare the differences in scheduling. What is the processing (Edit) time of operation 20? What is the lead time of the routing in days? a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today’s date as the start date, select Forward as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

In the Scheduling Overview, select the Scheduling Results icon . Make note of the lead time in days for the entire routing.

g)

Choose the Gantt chart icon

.

and view the schedule graphically.

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Lesson Summary You should now be able to: • Demonstrate the use of interoperation times in the routing for job shop related environments • Demonstrate the use of Overlapping for a continuous manufacturing process • Demonstrate the use of splitting for multi-capacity work centers.

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Trigger Points in the Routing Lesson Duration: 30 Minutes

Lesson Overview In this lesson you will learn how trigger points can be used to trigger actions in the production order. You will use a standard trigger point to create a specific trigger point for your routing.

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

Describe the use of trigger points to streamline and automate several administrative processes

Trigger points can be used to trigger other actions in the system automatically. In this unit we will demo creating standard trigger points. Then we will use these trigger points to insert an operation from a reference operation set and then another example to create a production order by copying a reference operations set. For time sake, we decided not to include another exercise so the demonstrations were included in the participant manual as procedures so students have the documentation for future reference.

Business Example As a production planner/scheduler, you are responsible for modeling the production process of several materials in SAP ERP. Several of your assembles undergo a very sophisticated manufacturing process. Due to the complex nature of the process, it often yields product that needs to be reworked during the process, as well as after the final process is complete. Your company has asked you to find a way to automate the rework business process at the time rework is reported during production confirmation. You need to investigate trigger points as a way of automating the rework process.

Defining Trigger Points Trigger points are assigned to operations in a routing to trigger certain functions in the production order at a later time. Trigger points can trigger functions when an operation’s status changes or when an operation is confirmed.

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Figure 135: Using Trigger Points in Routings

The person making the confirmation decides if the function is triggered when the operation is confirmed. Trigger points can trigger the following functions: • • • • •

•

Release succeeding operations. You can release all operations that follow the operation which has the trigger point assigned to it. Release up to stop indicator. You can release all operations up to and including the next operation for which the RelStop indicator is set. Release preceding operations. You can release all operations before the operation with the trigger point assigned to it. Create order by copying. You can create a new order without reference to a material by copying a reference operation set. Insert reference operation set. You can insert a reference operation set into an existing order. To do this, you must enter the operations between which you would like to insert the reference operation set. Start workflow task (for example, send mail to a user)

Standard trigger points can be copied to create new trigger points. If you copy a standard trigger point to create a trigger point, the system automatically transfers all necessary data from the standard trigger point into the trigger point you are creating. This reduces the time and work involved in creating a trigger point.

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Figure 136: Trigger Point Structure

You can combine several standard trigger points into a trigger point group. If you copy from a trigger point group, the system automatically transfers all standard trigger points in the trigger point group to the operation. Using trigger point groups considerably reduces the time and work involved in creating trigger points. You can maintain trigger point groups in Customizing.

Demonstration: Setting Up a Trigger Point Purpose

System Data System: TE3 Client: 800 User ID: PLM114-## Password: Set up instructions: None needed. 1. Create a trigger point that creates a rework operation when scrap is confirmed. Assign the trigger point to operation 20 on your reference operation set.

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2.

Use menu path Logistics → Production → Master Data → Standard Trigger Points → Standard trigger pt → Create or use transaction CO31.

3.

Enter REWORK## as the Std Triggerpoint and Insert Rework Reference Operation Set as the description.

4.

In Usage select TrigPointFuncts, select User Status profile PP000006 and press enter.

5.

Select Insert Reference Operation Set, User status NAVO, + Status set, and press enter.

6.

Enter group number 50000001, group counter 1 and save.

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7.

Now change your reference operation set by assigning this trigger point to operation 20.

8.

In the operations overview, select operation 20 and choose Goto → Trigger point overview.

9.

Select copy standard trigger point, select trigger point rework##, and save.

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Setting Up a Trigger Point 397

1.

Choose Logistics → Production → Master Data → Standard Trigger Points → Standard trigger pt → Create or use transaction CO31.

2.

Enter the Std Triggerpoint name and description.

3.

Assign a usage and group if you want.

4.

In Usage, select the function the trigger point should serve: TrigPointFuncts or Release Stop. •

•

TrigPointFuncts: The trigger point triggers the functions you entered on the detail screen for trigger points (for example, release operation or include reference operation set). Release Stop: The operation is the last in a series of operations released by the trigger point. If the function release up to stop was triggered in a previous operation, all subsequent operations are released up to the operation with the RelStop indicator

5.

Assign a User Status profile and press ENTER.

6.

Select the function the trigger point should execute, along with the system or user status and how it is initiated.

7.

In trigger point parameters, assign the group number and counter or any additional data that is needed.

Demonstration: Rework Operations and Orders During the Production Order Confirmation Process Purpose

System Data System: Client: User ID: Password: Set up instructions: 1. Create a production order with type PP01 for 10 PCs of 100-301 due in one week. Release and save the order. Use menu path Logistics → Production → Production Control → Order → Create → With Material or use transaction CO01.

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2.

Enter a final confirmation for operation 30 of your order for 8 pieces and 2 scrap with reason 0004. Use menu path Logistics → Production → Production Control → Confirmation → Enter → For Operation → Time Ticket or use transaction CO11N. Acknowledge any messages and show dialog box of reference operation set being added to order.

3.

Display order and show operation 32 has been added to order for rework. Use menu path Logistics → Production → Production Control → Order → Display or use transaction CO03.

4.

Now enter a final confirmation for operation 60 of your order for 8 pieces and 2 scrap with reason 0005. Use menu path Logistics → Production → Production Control → Confirmation → Enter → For Operation → Time Ticket or use transaction CO11N. Acknowledge any messages and show dialog box of rework order being created with reference operation set.

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Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson: Trigger Points in the Routing

Lesson Summary You should now be able to: • Describe the use of trigger points to streamline and automate several administrative processes

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Lesson: 399

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Scrap and Its Effects Lesson Duration: 25 Minutes

Lesson Overview In this lesson you will look at the different ways to define scrap in the SAP ERP system, and what effect they have on planning.

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

Explain how the assembly and component scrap in the material master field affect the production process Explain how the component scrap and operation scrap percentage in the bill of material affect the production process Explain how the scrap in the percentage field in the routing affects the production confirmation process

Business Example As a production planner/scheduler you are responsible for meeting customer services demands placed on you by the forecast and sales orders. Several of the production processes that you are responsible for scheduling are quite complex and yield loss is quite high. To assure that you deliver enough good production to inventory, you need to factor in these losses ahead of time. You want to examine the options in the bill of material, the material master, and the routing so you can properly model your scrap allowances.

Calculating Scrap You can calculate and plan the scrap quantity that will result from production. These scrap quantities are then included in the planning run and in the calculation of production costs. Which calculation the system uses depends on the settings in the material master record, the BOM, or the routing. The scrap quantity is settled

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Lesson: Scrap and Its Effects

against the net requirements quantity. Scrap is used for material requirements planning and product costing. The three scrap calculation procedures supported by the system are: • • •

Assembly scrap Component scrap Operation scrap

Figure 137: Scrap Categories and Their Effect

Assembly Scrap You use this function to plan the scrap that results from the production of an assembly. Assembly scrap increases the order quantity of the assembly and, subsequently, increases the order quantity for each component in the BOM of the assembly by adjusting the quantity of the dependent requirements generated during the MRP run. The system automatically increases the quantity to be produced by the percentage of scrap. However, the system always uses the estimated yield for the availability calculation for the assembly. Furthermore, the estimated yield of the assembly is always displayed in the MRP list or in the stock/requirements list. Assembly scrap is only used when the material is an assembly. Reasons for assembly scrap include inadequate quality or bad working conditions, such as heat, cold, or dampness.

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Demonstration: Assembly Scrap in Planned and Production Orders Purpose To demonstrate the effects of assembly scrap on the planned quantities in the planned and production orders.

System Data System: TE3 Client: 800 User ID: PLM114-## Password: Set up instructions: All data for this demo should already exist in the system and no system setup is needed. 1. Change the material master of your pump R-B1## to plan for 12% assembly scrap on MRP1 View. Also change the planning strategy to 40 on MRP3 View. MM02

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2.

Change the routing so operations 10, 20 and 40 each have standard times of 10 pc per 60 min and operations 30 has a standard time of 5 pc per 60 min. Also assign components 20 and 30 to operation 30. CA02

3.

Enter a Planned Independent Requirement for 100 PCs 2 months from today. MD61

4.

Run Single-Item Multi-Level MRP. MD02

5.

Show the SRList quantities. With 10 in stock 90 is needed and it shows a planned order for 90. However, display the details of the planned order and it shows a planned order for 101 with 11 scrap which nets to 90. Show the component details and the requirement quantities for all components reflect the increased quantity due to scrap. MD04

6.

Convert the planned order to a production order. The quantity in the production order is the same as the planned order. Show the component overview and the components are the same as the planned order. Now show the operation overview, select all operations, and click details. Choose the Qties/Activities tab and all operations show operations Qty of 101 and an increase in operations time to produce the extra quantities for scrap. Exit the production order without saving.

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Lesson: Scrap and Its Effects

Component Scrap You use this function to plan the scrap of a component that may break during production of an assembly. You can define component scrap in two places: • •

In the BOM on the Item Detail Screen: General Data (quantity data section). This component scrap is only relevant for the individual BOM. In the material master (MRP 4 view) in the Component scrap field. This component scrap is relevant for all BOMs.

The component scrap quantity maintained for a material component in the BOM has the higher priority. Component scrap increases the dependent requirements quantity of the component. If a scrap quantity is planned for a higher-level assembly, assembly scrap and component scrap are both added to the component level. Component scrap relates only to the individual components in an assembly. During BOM explosion, the system increases only the component quantity by the calculated scrap quantity.

Demonstration: Component Scrap in Planned and Production Orders Purpose To demonstrate the effects of component scrap on the planned quantities in the planned and production orders and the interaction of the two.

System Data System: TE3 Client: 800 User ID: PLM114-## Password: Set up instructions: All data for this demo should already exist in the system and no system setup is needed. 1. Change the material masters of your pump components R-T1##, R-T2##, and R-T3## to plan for 2%, 3%, and 7% component scrap respectively. MM02

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2.

Run Single-Item Multi-Level MRP and be sure to use planning mode 3 to delete and recreate all planned orders. MD02

3.

Show the SRList quantities. As compared to using assembly scrap, the SRList did not change and the details of the planned order also stayed the same. However, the component quantities have now increased to reflect the component scrap quantities in addition to the increase from the assembly scrap. MD04

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4.

Convert the planned order to a production order. The only changes in the production order is the component quantities. Be sure to show the operations again. Exit the production order without saving.

5.

Now change the BOM for R-B1## and enter component scrap of 20, 30, and 70 % respectively for R-T1##, R-T2##, and R-T3##. CS02

6.

Run Single-Item Multi-Level MRP and be sure to use planning mode 3 to delete and recreate all planned orders. MD02

7.

Show the SRList quantities. The SRList did not change and the details of the planned order also stayed the same. However, the component quantities have now increased to reflect the component scrap in the BOM. The component scrap in the material master has been ignored. MD04

8.

Convert the planned order to a production order. The only changes in the production order is the component quantities. Be sure to show the operations again. Exit the production order without saving.

9.

Change the BOM by deleting the component scrap quantities.

Operation Scrap Before high-value components are built into an assembly, your manufacturing process may require a quality control check of the assembly. Faulty materials that were taken into account in assembly scrap are not passed on to the next operation; they are removed from the manufacturing process. Therefore, for a high-value component, you plan using operation scrap instead of general assembly scrap. This scrap quantity refers to the quantity of one component that is to be processed in an operation, meaning that the planning run is more exact and you can determine service and quantity consumption more precisely. If the component is contained in an assembly for which an assembly scrap quantity has been maintained, the system only takes the operation scrap into account. The net indicator instructs the system to calculate the component operation scrap without taking assembly scrap into account (net usage scrap). You should also set the net indicator if operation scrap has not been maintained and assembly scrap has been entered. The assembly scrap should not, however, be taken into account. Operation scrap in the BOM relates to the quantity of a component to be processed in an assembly. The specification replaces the estimated assembly scrap for the high quality materials and allows for more precise MRP. The net indicator controls the operation scrap for components and is calculated without taking into account the assembly scrap (net input quantity). You still have to set this indicator if no operation scrap has been maintained and the assembly scrap is not to be taken into account.

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Lesson: Scrap and Its Effects

Operation scrap in the operation results in a fall in quantity in the next operation, and is taken into consideration in scheduling and costing. The scrap percentage maintained in the operations is added to the material master with the scheduling update.

Demonstration: Operation Scrap in Planned and Production Orders Purpose To show the effect of operation scrap on the planned and production orders and how they interact with assembly and component scrap with and without the Net ID.

System Data System: TE3 Client: 800 User ID: PLM114-## Password: Set up instructions: All data for this demo should already exist in the system and no system setup is needed. 1. From the previous demos we now have 12% assembly scrap for R-B1## and 2, 3, and 7 % component scrap for R-T1##, R-T2##, and R-T3## respectively.

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2.

Now change the BOM for R-B1## to add operation scrap of 5% for R-T1##. Show that the system requires you to select the Net ID. For components R-T2## and R-T3## select just the Net ID.

3.

Run Single-Item Multi-Level MRP and be sure to use planning mode 3 to delete and recreate all planned orders. MD02

4.

Show the SRList quantities. The SRList did not change and the details of the planned order also stayed the same. However, the component quantities have changed. The planning now ignores the assembly scrap and doesn’t plan enough quantity for any of the components. MD04

5.

Convert the planned order to a production order. The components quantities are the same as the planned order and will be short. In the operation details on the Qty/Activities tab the production time did not plan for any extra time. Exit the production order without saving.

6.

Now change the routing to add 5% operation scrap to both operations 10 and 20.

7.

Run Single-Item Multi-Level MRP and be sure to use planning mode 3 to delete and recreate all planned orders. MD02

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8.

Show the SRList quantities. No quantities have been affected by the operation scrap. The operation scrap in the BOM has been ignored and only the routing operation scrap is being planned. MD04

9.

Convert the planned order to a production order. The components quantities are the same as the planned order and will be short. In the operation details on the Qty/Activities tab the operation quantities have been adjusted to reflect the operations scrap and the production times have also been adjusted. Exit the production order without saving.

10. Change the BOM by deleting the operation scrap and all the Net IDs for each component. 11. Now schedule the routing and update both the production time and assembly scrap in the material master. 12. Run Single-Item Multi-Level MRP and be sure to use planning mode 3 to delete and recreate all planned orders. MD02 13. Show the SRList quantities. The correct quantities are now planned for the components. MD04 14. Convert the planned order to a production order. The correct quantities are planned for the components. In the operation details the system has now planned for the correct operation quantities and production times.

Scrap Example

Figure 138: Scrap Example

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Lesson: Scrap and Its Effects

Assembly scrap in the material master can be calculated from operation scrap entered in the routing. The following example shows how the assembly scrap is calculated. Formula: total scrap quantity (9.75) divided by total yield quantity (90.25) equals 10.80%. Even though the unit of measure is pc, there is no rounding in the scrap calculation. Operation

Scrap

Start Qty

Scrap Qty

Op Yield

10

5%

100

5

95

20

5%

95

4.75

90.25

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

Req Op

Asmbly Scrap

Comp Scrap

BOM Scrap

Op Net Ind

Req Qty

Blank

10

12%

2%

0%

N

115

Gasket

30

12%

3%

0%

Y

103

Screws

30

12%

7%

0%

Y

107

Execution time is also adjusted for the scrap quantities.

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Operation

Production Qty

Time Target Required Time

10

112

10 H

11.2 H

20

106

10 H

10.6 H

30

101

5H

20.2 H

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Exercise 23: Scrap in Production Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Maintain scrap in the material master, BOM, and routing • Maintain and use assembly scrap, component scrap, and operation scrap • Use the operation net indicator in planning scrap • Use operation scrap in the routing to update assembly scrap in the material master

Business Example Your production for the pump casing creates scrap in several different areas. You need to use assembly scrap, component scrap, and operation scrap to accurately plan the required quantities. You also want to use the operations scrap in the routing to update the assembly scrap in the material master without planning scrap for both.

Task 1: Maintain assembly scrap, component scrap, and operation scrap in your pump production. 1.

Change the material master of your pump R-B1## to plan for 12% assembly scrap.

2.

Change the material masters of your pump components R-T1##, R-T2##, and R-T3## to plan for 2%, 3%, and 7% component scrap, respectively.

3.

Change the BOM of your pump R-B1## so planning does not plan for both operation and assembly scrap by setting the operation net indicator for R-T2## and R-T3##.

4.

Change your routing for the production of material R-B1## in plant 1000 to reflect the operation scrap of 5% that occurs at operations 10 and 20. Also, adjust the standard values of the first three operations to match the data in the table below. Standard Processing Times:

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Activity

Op 10

Op 20

Op 30

Base Quantity

10 PC

10 PC

5 PC

Setup

10 Min

3 Min

0 Min

Machine

60 Min

60 Min

60 Min

Labor

60 Min

60 Min

60 Min

Scrap in %

5

5

0

Task 2: Test the scrap calculation by scheduling a production order for material. 1.

Schedule a production order for 100 pieces of R-B1## due in two months.

2.

Analyze the component quantities and operation times to be sure the system planned properly for scrap.

Task 3: Update the material master record with the operation scrap from the routing. 1.

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Update the material master record of R-B1## with the operation scrap from the routing.

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Lesson: Scrap and Its Effects

Solution 23: Scrap in Production Task 1: Maintain assembly scrap, component scrap, and operation scrap in your pump production. 1.

2.

Change the material master of your pump R-B1## to plan for 12% assembly scrap. a)

Choose Logistics → Production → Master Data → Material Master → Material → Change → Immediately or use transaction code MM02.

b)

Enter R-B1## for the material number, choose the MRP1 and MRP3 views, and enter plant 1000.

c)

In the section for Lot Size Data, enter 12 in the Assembly scrap (%) field. On the MRP3 view be sure the Strategy Group is set to 40 and save.

Change the material masters of your pump components R-T1##, R-T2##, and R-T3## to plan for 2%, 3%, and 7% component scrap, respectively. a)

Choose Logistics → Production → Master Data → Material Master → Material → Change → Immediately or use transaction code MM02.

b)

Enter R-T1## for the material number, choose the MRP4 view, and enter plant 1000.

c)

In the section for BOM explosion/dependent requirements data, enter 2 in the Component scrap (%) field and save.

d)

Repeat steps b through c for each of the other materials, R-T2## and R-T3##, and enter the correct scrap quantity for each.

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3.

4.

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Change the BOM of your pump R-B1## so planning does not plan for both operation and assembly scrap by setting the operation net indicator for R-T2## and R-T3##. a)

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

b)

Enter material R-B1##, plant 1000, BOM usage 1, and choose Enter.

c)

In the General Item Overview, select components R-T2## and R-T3##.

d)

Go to the Item details screen by choosing the Item icon

e)

In the Item details screen, select the Net ID for R-T2##.

f)

Choose Next

g)

Select the Net ID and save your BOM.

.

to move to the details of R-T3##.

Change your routing for the production of material R-B1## in plant 1000 to reflect the operation scrap of 5% that occurs at operations 10 and 20. Also, adjust the standard values of the first three operations to match the data in the table below. Standard Processing Times: Activity

Op 10

Op 20

Op 30

Base Quantity

10 PC

10 PC

5 PC

Setup

10 Min

3 Min

0 Min

Machine

60 Min

60 Min

60 Min

Labor

60 Min

60 Min

60 Min

Scrap in %

5

5

0

a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter the material R-B1## and plant 1000 and choose Enter

c)

Select operations 10, 20, and 30 and choose Details → Operation from the menu. Enter the base quantity and the standard operation processing times from the table. Scroll down to enter the scrap values and choose to navigate to the next operation detail screen. Continue until all times and scrap quantities have been entered and then choose to return to the operation overview. Be sure you save your routing.

.

Continued on next page

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Task 2: Test the scrap calculation by scheduling a production order for material. 1.

2.

Schedule a production order for 100 pieces of R-B1## due in two months. a)

Choose Logistics → Production → Production Control → Order → Create → With Material or use transaction code CO01.

b)

Enter material R-B1##, production plant 1000, and order type PP01 and choose Enter.

c)

Enter Total Qty of 100, a Basic Finish date 2 months from today and hit ENTER.

d)

Stay in the production order without saving.

Analyze the component quantities and operation times to be sure the system planned properly for scrap. a)

In the production order, choose Component overview

b)

You should see in the component overview that the system has planned the following: Component

Reqmts qty

R-T1##

115

R-T2##

103

R-T3##

856

.

c)

Choose Operations overview

d)

Select operations 10, 20, and 30 and select the Op. details icon the lower left of the screen.

e)

Select the Qty/activities tab and compare the data to the table below.

f)

.

Operation

Operation Qty

To confirm time

10

112

11.2 H

20

106

10.6 H

30

101

20.2 H

in

When you are finished and are satisfied the production order was scheduled correctly, exit without saving by choosing and answering No to the dialog box.

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Task 3: Update the material master record with the operation scrap from the routing. 1.

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Update the material master record of R-B1## with the operation scrap from the routing. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Change or use transaction code CA02.

b)

Enter material R-B1##, plant 1000, and choose Enter

c)

From the menu, choose Extras → Scheduling → Schedule.

d)

Enter today’s date as the start date, select forward scheduling as the scheduling type, enter 100 for the lot size (these should all default), and choose Continue .

e)

Select the overview variant 000000000001 Operation segments and choose Continue .

f)

In the Scheduling Overview, select the Scheduling Results icon .

g)

In the dialog box that appears, you can compare the scheduling results with the current material master settings. Choose Update mat. master icon. in the dialog box.

h)

You should receive a message box that says, “Scheduling data marked for material master update.” Choose OK and back out of the routing.

i)

Choose Logistics → Production → Master Data → Routings → Extras → Material Master → Update Material Master or use transaction code CA96.

j)

Enter plant 1000, production planner 0##, and choose Enter

k)

Select your material from the list and be sure to select the Update with assembly scrap indicator. Now choose Update mat. master icon. on the tool bar and check your material master record to be sure it updated correctly.

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.

.

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Lesson: Scrap and Its Effects

Lesson Summary You should now be able to: • Explain how the assembly and component scrap in the material master field affect the production process • Explain how the component scrap and operation scrap percentage in the bill of material affect the production process • Explain how the scrap in the percentage field in the routing affects the production confirmation process

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Production Resources/Tools Lesson Duration: 20 Minutes

Lesson Overview This lesson explains how to create and use production resources/tools.

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

Describe and use production resources/tools in the routing

Business Example As a production scheduler, several of your products require extensive testing. The testing process requires expensive and sophisticated equipment. For the purpose of informing the quality department of its need and duration of use, you think it might be useful to model in on the production floor. In order to do this you will use production resources/tools in the routing

Production Resources/Tools Production resources/tools are required for production but are not consumed. A PRT may be needed in order to carry out an operation and therefore must be assigned to that operation. The PRT must be identified by a material master, equipment 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.

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Lesson: Production Resources/Tools

Figure 139: Production Resources/Tools

The ECC System differentiates between the following types of production resources/tools, according to their properties and business function: • • • •

Materials that are accounted for in materials management, for instance in inventory management, requirements planning and procurement. Equipment, for instance measuring instruments or valuable tool, which are serviced Documents, for instance drawings or programs, which use the document management system. Miscellaneous production resources/tools (with a PRT master record), that require less maintenance in the system.

Production resources/tools can be assigned to operations, activities or phases in task lists (including standard networks and recipes), production orders and maintenance orders as well as networks. Production resources/tools that are used for testing during production, can be assigned to the corresponding inspection characteristic in the inspection plan. 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).

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Figure 140: PRT Categories

Demonstration: Assigning Material Components and Production Resources/Tools Purpose This demonstration will familiarize the participants with PRT categories and the process of assigning materials and PRTs to an operation.

System Data System: T34 Client: 8## User ID: PLM111-## Password: init Set up instructions: 1. Assign a PRT to operation 20 in your routing.

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2.

Demonstrate a search with matchcode for the PRT material type and select the PP-FHMM PRT.

3.

Show how a PRT of the Other type is created.

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415

Exercise 24: Creating and Assigning PRTs Exercise Duration: 10 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create a PRT • Assign a PRT to an operation on a routing

Business Example In your production process, you have production inspection tools that are needed for testing pumps. You need to create these as PRTs and assign them to your inspection operations on the routing.

Task 1: Create a PRT to represent your inspection gauge. 1.

Create a miscellaneous PRT called INSP-## to represent your inspection gauge. Be sure you release it for use in production, allow it to be used only for routings, and the unit of measure is pieces.

Task 2: Assign a PRT to your inspection operation of your reference operation set.

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1.

Assign a PRT inspection gauge to operation 10 of your reference operation set.

2.

Display your routing for T-F## and plant 1000 to ensure the PRT is visible there also.

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Solution 24: Creating and Assigning PRTs Task 1: Create a PRT to represent your inspection gauge. 1.

Create a miscellaneous PRT called INSP-## to represent your inspection gauge. Be sure you release it for use in production, allow it to be used only for routings, and the unit of measure is pieces. a)

Choose Logistics → Production → Master Data → Production Resources and Tools → Production Resources/Tools → PRT Master (Misc.) → Create or use transaction code CF01.

b)

Enter INSP-## and press ENTER.

c)

Enter Inspection Gauge ## as the description, Status 03, Task List Usage 001, and Base Unit of Measure PC.

d)

Choose the Default icon to go to the default view.

e)

Enter Control Key 1 for all business processes, Ref. start date as 04 Start Date for execution, and Ref. date for finish as 05 Start date for wait.

f)

Save your PRT.

Continued on next page

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Lesson: Production Resources/Tools

Task 2: Assign a PRT to your inspection operation of your reference operation set. 1.

2.

Assign a PRT inspection gauge to operation 10 of your reference operation set. a)

Choose Logistics → Production → Master Data → Routings → Routings → Reference Operation Sets → Change or use transaction code CA12.

b)

Enter the group number of your reference operation set or search for it using S:RefOpSet and your Planner numbeer 0## and choose Enter .

c)

Acknowledge the warning message that appears. This message means that upon saving, any changes made to the reference operation set will update all routings to which it is assigned.

d)

Select operation 10 and choose Prod.resources/tools icon..

e)

The dialog box that appears defaults to material PRT. If you want to assign a different PRT, you must choose the appropriate button at the bottom of the box. Choose Others to assign a miscellaneous PRT.

f)

Enter INSP-## as the name of the Prod.resource/tool and press ENTER. Respond to any messages that appear.

g)

Save the reference operation set.

Display your routing for T-F## and plant 1000 to ensure the PRT is visible there also. a)

Choose Logistics → Production → Master Data → Routings → Routings → Standard Routings → Display or use transaction code CA03.

b)

Enter material T-F##, plant 1000, and choose Enter

c)

In the operations overview, be sure the PRT column is selected for both operations 25 and 35.

d)

Select one of those operations and choose Prod.resources/tools

.

. e)

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The PRT INSP-## should be visible.

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Lesson Summary You should now be able to: • Describe and use production resources/tools in the routing

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Unit Summary

Unit Summary You should now be able to: • Use parallel sequences in modeling complex manufacturing processes • Use alternative sequences in modeling flexible manufacturing processes • Model alternative manufacturing processes using alternative routings • Use production versions to model a very specific production process • Utilize reference operation sets to minimize routing maintenance • Create a reference operation set • Use a reference operation set in a routing • Use a reference operation set as a template to create a routing • Describe in detail the concept of lead time scheduling and updating in-house production time in the material master • Identify the data used in lead time scheduling • Explain how the SAP ERP system uses the data to determine the lead time schedule • Update the material master record of a material from the routing • Demonstrate the use of interoperation times in the routing for job shop related environments • Demonstrate the use of Overlapping for a continuous manufacturing process • Demonstrate the use of splitting for multi-capacity work centers. • Describe the use of trigger points to streamline and automate several administrative processes • Explain how the assembly and component scrap in the material master field affect the production process • Explain how the component scrap and operation scrap percentage in the bill of material affect the production process • Explain how the scrap in the percentage field in the routing affects the production confirmation process • Describe and use production resources/tools in the routing

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Unit Summary

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421

Test Your Knowledge

Test Your Knowledge 1.

Float time that can be modeled in the scheduling of the routing include: Choose the correct answer(s).

□ □ □ □ □ 2.

A B C D E

Float before production Float after production Setup time Queue time Teardown time

The duration of an operation consists of a maximum of 5 components. Determine whether this statement is true or false.

□ □ 3.

True False

Teardown and wait time are always scheduled simultaneously. Determine whether this statement is true or false.

□ □ 4.

True False

Only the minimum wait time is scheduled. Determine whether this statement is true or false.

□ □ 5.

True False

Move time is defined only in the operation details. Determine whether this statement is true or false.

□ □ 6.

True False

You can only split an operation processing time on a work center with more than 1 individual capacity. Determine whether this statement is true or false.

□ □

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True False

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Test Your Knowledge

7.

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Operation can be set to overlap so that the next operation starts before the previous operation has finished. Determine whether this statement is true or false.

□ □ 8.

True False

Reduction measures are applied when the lead time schedule of a routing does not fit within the basic date schedule. Determine whether this statement is true or false.

□ □ 9.

True False

Which of the following are types of PRT’s? Choose the correct answer(s).

□ □ □ □ □

A B C D E

Material Equipment Component Miscellaneous Document

10. PRT is another name for a component that is used in production. Determine whether this statement is true or false.

□ □

True False

11. The same PRT can be assigned to more than one operation on the same routing. Determine whether this statement is true or false.

□ □

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Test Your Knowledge

Answers 1.

Float time that can be modeled in the scheduling of the routing include: Answer: A, B, D Float time that can be modeled in the scheduling of the routing include the float before and after production and queue time sometimes referred to as operation float time.

2.

The duration of an operation consists of a maximum of 5 components. Answer: True The duration of an operation consists of a maximum of 5 components which are queue time, setup time, processing time, teardown time, and wait time.

3.

Teardown and wait time are always scheduled simultaneously. Answer: False Teardown and wait time are scheduled consecutively unless the teardown/wait simul. indicator is set in the operation details of the routing.

4.

Only the minimum wait time is scheduled. Answer: True Only the minimum wait time is scheduled, the maximum wait time is used for information purposes only.

5.

Move time is defined only in the operation details. Answer: False Move time can be defined in the operation details or by location groups in the work center.

6.

You can only split an operation processing time on a work center with more than 1 individual capacity. Answer: True An operation is split if it is carried out on several machines or by several persons at the same time.

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Operation can be set to overlap so that the next operation starts before the previous operation has finished. Answer: True To reduce lead time of a routing or production order you can overlap operations. This means that an operation starts before the previous operation has finished.

8.

Reduction measures are applied when the lead time schedule of a routing does not fit within the basic date schedule. Answer: True Reduction measures are applied when the lead time schedule of a routing does not fit within the basic date schedule

9.

Which of the following are types of PRT’s? Answer: A, B, D, E The 4 types of PRT’s are material, equipment, document, and miscellaneous.

10. PRT is another name for a component that is used in production. Answer: False PRT’s like components are needed for production but they are not consumed like components which makes them much different than components. 11. The same PRT can be assigned to more than one operation on the same routing. Answer: True Unlike components, PRT’s are not consumed in the production process and the same PRT can be assigned to multiple operations on the same routing.

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In this unit you will instruct participants on other alternatives user interfaces that can be used to create and change engineering data. The Engineering Workbench and the PLM Web UI can be used to access master data objects. These very different tools have different functionality and different uses.

Unit Overview This unit introduces the engineering workbench and the PLM Web User Interface to create and maintain various production planning and execution master data. These transactions can replace the create and change functions for most master data objects.

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

Use the engineering workbench for routing maintenance Use the EWB browser functions Navigate in the engineering workbench Create a work area Explain the effect of the work area focus Explain the effect of objects contained in the work area Explain the use of the PLM Web UI. Navigate in the PLM WEB UI Maintain master data objects using the PLM Web UI

Unit Contents Lesson: Structure of the Engineering Workbench ..........................487 Lesson: Navigating in the Engineering Workbench .......................494 Demonstration: Material-Routing Assignment and Lock Logic .......498 Exercise 25: Navigating in the EWB .....................................501 Exercise 26: Navigating in the EWB II...................................505

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Lesson: Engineering Workbench Work Areas ..............................512 Exercise 27: Create a Work Area ........................................521 Lesson: Introduction to the PLM Web User Interface ......................526 Demonstration: PLM Web UI Navigation and Search Function ......533 Demonstration: Using the Work Center to Change a BOM with ECM ..........................................................................536 Exercise 28: Using the PLM Web User Interface ......................543

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Lesson: Structure of the Engineering Workbench

Structure of the Engineering Workbench Lesson Duration: 40 Minutes

Lesson Overview In this lesson you will learn the benefits of using the engineering workbench. You will learn to navigate in the tool, create your own work area, and copy multi-level.

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

Use the engineering workbench for routing maintenance Use the EWB browser functions

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

Introduction to the Engineering Workbench The engineering workbench (EWB) is part of the PP module in SAP R/3, and is a complex tool for the integrated processing of BOMs and routings. This means that both object types and their links are maintained simultaneously and in detail, with the same user interface.

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Figure 141: Benefits of the Engineering Workbench

The concept of the engineering workbench however, goes far beyond the conventional maintenance of BOMs and routings in that all transactions for the conventional maintenance of these objects are brought together and an extensive change management is offered. Using complex selection criteria, any number of objects can be combined; the resulting data then contains no additional information, helping you to achieve a quick overview. The integration of an object browser, as well as various viewers and the digital mock-up viewer, makes the workbench a central object within PLM.

Figure 142: Formatting of Specific Information

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Often times changes to master data happen in complex processes and groups. These activities can arise from new development, design changes, or changes in procedure. Design changes can be changes that are required due to new products, rules, warranty dates, and so on. Technical changes can occur in BOMs, routings, or new steps in the process (work center). These types of changes call for simultaneous changes to the assembly in the BOMs and to the sequence in the routings.

Figure 143: Worklist: Purpose

The engineering workbench is a maintenance environment for product structures and PP objects. Its capabilities far exceed those of the conventional maintenance of BOMs and routings because you do not have to process routings and BOMs separately. The most important objects of the engineering workbench are BOM items and operations. Views are applied to these objects, which then further enable the conventional BOM or routing structures to be used. The full scope of the processing functions, Create, Change, and Delete, is supported in all these views. The worklist contains the selected objects so that they can be displayed, changed, or newly created in the engineering workbench. These objects are copied by the system from the database into the worklist. Only when the worklist has been saved, following the processing of objects, are new objects created in the database or existing ones changed or deleted.

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Figure 144: Simultaneously Processing Objects in EWB

Different users can work on the same BOM and /or routing simultaneously without locking each other out. Any number of operations from any number of routings can be processed at the same time by different people. The same applies to different BOM items or different operations. If you want to process an object that is already being processed by someone else, the engineering workbench information will show you who to contact, so that you can consult with the other processor. The processor can then release the object to you, without interrupting your work on other objects.

Structure of the Engineering Workbench To display or process an individual object using the EWB, you have to select the corresponding object. Examples of objects are: • • • • •

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The task list header of a routing The operation and sub-operation The production resource/tool, trigger point, and inspection characteristic The BOM header The item and sub-item in the BOM

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Figure 145: Structure of the Engineering Workbench

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

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Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson Summary You should now be able to: • Use the engineering workbench for routing maintenance • Use the EWB browser functions

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Navigating in the Engineering Workbench Lesson Duration: 45 Minutes

Lesson Overview In this lesson you will learn the benefits of using the engineering workbench. You will learn to navigate in the tool, create your own work area, and copy multilevel.

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

Navigate in the engineering workbench

Explain which data can be read in the working area.

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 it in a hierarchy.

Data Selection in EWB Work areas are created in Customizing for the engineering workbench. Using the Display work area button, you can specify a standard work area or select another work area. In the Select work area dialog box, you also have the option of branching to the detail screen in the working area. In this detail screen, you can read the information about the predefined focus and about the object types contained in the working area.

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Figure 146: Choosing the Work Area

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.

Figure 147: Selection Criteria

You can also use the selection range to restrict the time period for the data. Only data that lies entirely or partially in the validity period is copied into the worklist. By using the arrow key on the tab page, you can enter into fields additional selection criteria that is not contained as selection criteria in the tab pages on the screen. In addition, you can also use this procedure when you want to select according to several individual values, value intervals, or generically.

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Figure 148: Effectivity Window

With the help of the effectivity window, the display of objects is filtered into the overview screen. In this figure above, the example is of a working area with four operations. The operations have been partially changed. If you choose the selection period in the effectivity window, all operations that are effective in the selection period are displayed. If you restrict the effectivity window, the operations that lie completely outside of the effectivity window are not displayed. If you choose the key date in the effectivity window, only those operations that are effective on the key date are displayed.

Navigation in the Engineering Workbench The screen layout is divided into three elements: • • •

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Toolbar Cockpit Overview screen

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Figure 149: Navigation in the EWB

The toolbar provides the user with currently available functions at the touch of a button. The cockpit is always available and controls the engineering workbench. It consists of three areas: •

• •

Process using, for the entry of the key dates or of the change number, to process the objects in the worklist. The entry of a key date or a change number is necessary when an object has to be created, changed, or deleted. Effectivity window, to display a particular time segment of the worklist. Context, to display the hierarchical relationship of objects in the overview screen.

In this figure below there is an input line for each material, BOM, and item. The overview screen lists objects that are contained in the worklist and that match the entries in the effectivity window and in the context. It provides information about the object and change status of a particular object type.

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Figure 150: Functional Overview of the EWB

In the browser: • •

If you double-click on an object, the context block is filled in the EWB window and the tab page belonging to it is displayed. The right mouse button provides the functions from the graphics displayed above in a context menu.

Multilevel copy prerequisites: The copy range has to include the object to be copied. The copy range is predefined with the settings from the working area and also those from the restrictions. No objects an be expanded unless they are contained in the working area. Should the situation arise, check under Extras→ Options→ Copy range.

Demonstration: Material-Routing Assignment and Lock Logic Purpose This isn’t a valid use for this demo! Becoming familiar with operation copy features

System Data System: T34 Client: 8## User ID: PLM111-## Password: init Set up instructions: include settings here, do not refer to other exercises 1. Explain the locking properties of the EWB and work with a second session. Show how the changes are automatically compiled in the second session. NOTE: For the demonstration, it is important to switch on the locking

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mechanism again using the transaction SE38 and the program ZSENQON. Show the additional selection criteria and emphasize that these are saved for the user. Demonstrate the effects of switching to the effectivity window. Discuss the options in the Extras menu with the details for the selection criteria and the working area.

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Exercise 25: Navigating in the EWB Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Navigate in the engineering workbench • Select objects for your work list • Assign materials to routings using the EWB • Change BOMs and routing using EWB • Use EWB locking logic

Business Example You are responsible for maintaining master data for BOMs and routings in your company. To do this you want to use the common maintenance interface in the engineering workbench.

Task 1: Select the routings that you created. 1.

Using the P_ALLES working area, select all routings that you created.

2.

How many routings did you create?

3.

Check whether the groups displayed belong to your products.

Task 2: Using the EWB, create a material-routing assignment.

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1.

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

2.

In the BOM for pump P-100, change the quantity of the component 100-130 to the number of your group. Who currently has the data locked?

3.

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

4.

Save the changes and exit the EWB.

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Solution 25: Navigating in the EWB Task 1: Select the routings that you created. 1.

2.

Using the P_ALLES working area, select all routings that you created. a)

Choose Logistics → Production → Master Data → Engineering Workbench or use transaction code CEWB.

b)

Select the P_ALLES working area and choose Continue.

c)

Select the Additional Selection Criteria icon .

d)

On the Header tab page, choose More Selection Criteria task list section.

e)

In the Explorer window that appears, expand the Task list - Header folder by clicking the triangle to the left of it.

f)

Select Created by and choose Adopt Field Selection .

g)

Complete the field with your user ID and choose Save.

h)

Choose Load Task Lists and BOMs .

i)

In the Headers Overview you now see a list of task lists that you created.

How many routings did you create? a)

3.

under the

Four routings and one reference operation set.

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

From the menu, choose Task Lists → Material-Task list assignments.

b)

The Material - Routing Assignments Overview screen now shows which materials are assigned to your routings.

Continued on next page

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Task 2: Using the EWB, create a material-routing assignment. 1.

2.

3.

When creating the routing for your pump T-F##, it occurs to you that your routing can also be used for the production of pump P-100. Assign material P-100 to your routing. a)

Select the routing for T-F## from the list by clicking the button to the left of it in the table.

b)

Choose Task Lists → Material-Task List Assignment.

c)

Click the Create icon.

d)

Enter P-100 in the first blank line in the table and press Enter.

e)

The new assignment is created and appears on the list.

In the BOM for pump P-100, change the quantity of the component 100-130 to the number of your group. Who currently has the data locked? a)

Select the routing-material assignment for P-100 on the Material-routing assignments Overview screen and choose Bills of Material → BOM Headers from the menu.

b)

In the context section, replace T-F## with P-100, delete the BOM number, and choose Enter to load the BOM for P-100.

c)

Select the P-100 BOM header line in the table and use the EWB menu path Bill of Material → Items to display the components.

d)

Select the line with 100-130 and choose Change.

e)

If another group is changing the same item, a dialog box will appear specifying which group has the data locked.

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

4.

.

Yes.

Save the changes and exit the EWB. a)

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Exercise 26: Navigating in the EWB II Exercise Duration: 35 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Reassign component assignments • Use the browser to copy and an operation • Create a routing and a BOM by using multi-level copy

Business Example 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: Copy an operation for a similar pump. 1.

Copy operation 50 with its corresponding PRT’s from the routing for material T-F1## to operation 45 in the T-F## routing.

2.

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

Task 2: Your company is introducing a new pump T-H## which is similar to T-F## with 2 flywheels and an extra raw material T-P## assigned to operation 40.. You must create the master data needed to manufacture this new pump. 1.

First create the material master record for your new pump T-H## by using T-F## as the template and create your default views. Change the description to Rotary Pump W/2 flywheels GR##.

2.

Now create the rest of the master data using the Engineering Workbench. The routing should be copied multi-level from the pump with material number T-F## and group counter 1. Before copying, set the indicator for Set target context after copying on the Misc. tab page. After you copy the master data for the pump T-H##, add the component T-P## as a raw material with a quantity of 1. Continued on next page

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Task 3: Display the PRT assignments in the Engineering Workbench.

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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 INSP-## in your routings by using the browser. Navigate to the details screen.

3.

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

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Solution 26: Navigating in the EWB II Task 1: Copy an operation for a similar pump. 1.

2.

Copy operation 50 with its corresponding PRT’s from the routing for material T-F1## to operation 45 in the T-F## routing. a)

Use the menu path Logistics → Production → Master Data → Engineering Workbench or transaction code CEWB.

b)

Select the P_ALLES working area and click continue.

c)

Select the Additional Selection Criteria icon .

d)

Click Multiple Selection Icon to the right of material and enter T-F1## and T-F## as material numbers.

e)

Click the Load Task Lists and BOMs Icon .

f)

Confirm the dialog box EWB: Process Using with the specified key date if it appears.

g)

Click the Activate Browser Icon to activate the browser, enter application PP01 in the dialog box that appears.

h)

Expand the routing for T-F1## to the operations by clicking the triangle to the left of T-F1##. Use the same method to navigate to the operations for material T-F##.

i)

Click and drag operation 50 from material T-F1##, and drop it on the Standard Sequence of T-F##.

j)

Enter operation 45 in the dialog box that appears.

k)

The operation and PRT assignments now appear in the T-F## routing.

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

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

b)

Click save.

Continued on next page

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Task 2: Your company is introducing a new pump T-H## which is similar to T-F## with 2 flywheels and an extra raw material T-P## assigned to operation 40.. You must create the master data needed to manufacture this new pump. 1.

2.

First create the material master record for your new pump T-H## by using T-F## as the template and create your default views. Change the description to Rotary Pump W/2 flywheels GR##. a)

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

b)

Enter the material number T-H## and material type for Finished goods. Enter T-F## as the copy from material.

c)

In the Basic Data 1 view, change the description to Rotary Pump W/2 flywheels GR##.

d)

Choose Save

.

Now create the rest of the master data using the Engineering Workbench. The routing should be copied multi-level from the pump with material number T-F## and group counter 1. Before copying, set the indicator for Set target context after copying on the Misc. tab page. After you copy the master data for the pump T-H##, add the component T-P## as a raw material with a quantity of 1. a)

Use the menu path Logistics → Production → Master Data → Engineering Workbench or transaction code CEWB.

b)

Select the P_ALLES working area and click continue.

c)

Select the Basic Selection Criteria icon .

d)

Enter T-F## as the material number and 1000 as the Plant number.

e)

Click the Load Task Lists and BOMs Icon .

f)

First select the Options Icon , choose the Misc. tab and in the Navigate while copying section select Set target context after copying and click Execute.

g)

Select the T-F## routing you wish to copy and click the Copy Object Icon .

h)

In the Target Data dialog box, enter material number T-H##, plant 1000, task list type N Routing and delete the routing group number.

i)

Select the Multi-level Copy indicator. Continued on next page

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j)

Click the Copy Range Icon to set the indicators for the relevant copy objects (select all) in the EWB: Options dialog box.

k)

If you didn’t set it in step b) then in the EWB: Options dialog box, set the Set target context after copying indicator on the Misc. tab page.

l)

Now copy the routing by clicking the copy button.

m)

Change the lot-size validity in the table to 1-100,000 and scroll to the right to be sure planner 0## is assigned.

n)

Choose Bills of Material → Items.

o)

In the first open line enter T-P## and quantity 1 and click enter.

p)

Select Mechanical Engineering as the Industry sector and Raw Material as the Material Type in the dialog box that appears and click Enter.

q)

Click Cancel on the Select Views dialog box that appears next.

r)

Enter T-T0## as the Copy from material and click Enter.

s)

Select the default views except for the Sales views and add the Purchasing view since this is a raw material. Also be sure the Create views selected indicator is set then click Enter.

t)

Enter Plant 1000 and click Enter on the Organization levels dialog box.

u)

Change the description to Raw Material GR##.

v)

Choose Bills of Material → Component Assignments and assign your new component to operation 40.

w)

Save your data.

x)

Be sure to check the Component Assignments, the PRT assignments, the BOM Header, and BOM Items.

y)

Exit the Engineering Workbench.

Continued on next page

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Task 3: Display the PRT assignments in the Engineering Workbench. 1.

2.

3.

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

Use the menu path Logistics → Production → Master Data → Engineering Workbench or transaction code CEWB.

b)

Select the P_ALLES working area and click continue.

c)

Enter T-F1## and T-F## as material numbers using the selection icon.

d)

Click the Load Task Lists and BOMs Icon .

e)

Select the line in the table for the task list header for material T-F1## and use the EWB menu path Task Lists → Production Resources and Tools to display an overview of PRT’s assigned to the routing of T-F1##.

Multiple

Search for the production resource/tool INSP-## in your routings by using the browser. Navigate to the details screen. a)

Open the Browser by clicking showing.

b)

In the left panel Browser window, select Find

c)

In the Find dialog box, select the object type PRT and enter INSP-##.

d)

Double-click the search results (lower window) 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.

the Browser icon, if its not already .

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)

Drill down in the browser structure and reassign the hollow shaft to operation 45 by clicking and dragging.

b)

Close the browser and exit the EWB without saving.

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Lesson Summary You should now be able to: • Navigate in the engineering workbench

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Engineering Workbench Work Areas Lesson Duration: 20 Minutes

Lesson Overview In this lesson we will investigate the work area and how it affects work in the engineering workbench.

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

Create a work area Explain the effect of the work area focus Explain the effect of objects contained in the work area

Business Example Users will need specific work areas to allow them to do their jobs efficiently. You need to understand how to configure work areas to make them efficient for users in your company.

Work Areas Work areas are created in Customizing for the engineering workbench. Using the Display work area button, you can specify a standard work area or select another work area.

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Figure 151: Work Area Selection

In the Select work area dialog box, you also have the option of branching to the detail screen in the working area. In this detail screen you can read the information about the predefined focus and about the object types contained in the working area.

Figure 152: Objects in the Worklist

A focus object is an object of the focus object type that meets the selection criteria that you enter. An environment object is an object whose object type is contained in the working environment and that is assigned to a focus object. Environment objects are automatically selected by the system and represent the environment

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of the focus object that you are interested in. Using the selection criteria that you enter, you immediately determine which focus objects are contained in your worklist. The focus objects form the core of your worklist. An example would be 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.

Figure 153: Example: Focus BOM Header

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The focus lies on the object type BOM header. In addition to the focus on the BOM header, the object types item and subitem, routing header with sequence, operation, PRT, trigger point, and inspection characteristic should all be contained in the working environment. A component has been entered as selection criteria. 1. 2. 3.

4.

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

Figure 154: Example: Focus BOM Item

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The focus lies on the object type item. With the focus on the item, the following object types should also be included in the working environment: BOM header and subitem, routing header with sequence, operation, PRT, trigger point, and inspection characteristic. A component has been entered as selection criteria. 1. 2. 3.

4.

Only the items that correspond to these components, are copied into the worklist with their BOM headers and subitems. All operations to which this component has been assigned are copied in to the worklist. Additionally, the objects that are connected to this operation and whose object type is contained in the working environment are copied into the worklist, for example, task list header, sequence, and so on. As a further restriction, the material / routing assignment is taken into account.

Figure 155: Different Focus: BOM

These examples illustrate the expected results of a different focus. The prerequisite for these results is that the working area always contains the same object types. The working area (with focus) and the selection criteria can be viewed in the menu entry Extras: • •

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Working area Selection criteria

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Lesson: Engineering Workbench Work Areas

Figure 156: Different Work Areas: BOM

These examples illustrate the expected results of a different working area. The prerequisite for these results is that the focus is always on the same focus object. The working area (with focus) and the selection criteria can be viewed in the menu entry Extras: • •

Working area Selection criteria

As an example, the focus is defined in reference to the BOM header.

Figure 157: Example: Focus Task List Header

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The focus lies on the object type routing header. In addition to the focus routing header, the object types sequence, operation, PRT, trigger point, inspection characteristic, BOM header, item, and subitem should all be contained in the working environment. A work center has been entered as selection criteria. 1.

2. 3. 4.

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

Figure 158: Example: Focus Operation

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The focus lies on the operation object type. In addition to the focus operation, the following object types should all be contained in the working environment: routing header, sequence, PRT, trigger point, inspection characteristic, BOM header, item, and subitem. A work center has been entered as selection criteria. 1. 2. 3. 4.

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

Figure 159: Routing: Different Focus

The figure above illustrates the expected results of the different focus. Prerequisite for the respective result is that the working area always contains the same object types. The working area (with focus) and the selection criteria can be viewed by choosing Extras → Working Area Details → Selection Criteria Details.

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Figure 160: Routing: Different Work Area

The figure above illustrates the expected results of a different working area. A prerequisite for the respective results is that both examples use the same focus. The working area (with focus) and the selection criteria can be viewed by choosing Extras → Working area details → Selection criteria details.

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Exercise 27: Create a Work Area Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create a work area for use in the engineering workbench

Business Example You need to create different work areas for different users in the engineering workbench.

Task 1: Create a work area with focus on the BOM header and use it to make a change in a BOM. 1.

Create a work area called PLM## with focus on the BOM header.

2.

Use your new work area to make a change to the quantity of component 30 of the BOM of T-F##. What is missing in the work area that prevents you from making this change?

Task 2: Change your work area to focus on the task list header and include task list header, operations, and material-routing assignments in the work area. Use you work area to assign BOM components to an operation on the routing. 1.

Change your work area, PLM##, to focus on the task list header. Include task list header, operations, and material-routing assignments in the work area.

2.

Use your new work area to assign material components of the BOM of T-F## to operations. What is missing in the work area to be able to make this change?

Task 3: Change your work area to focus on the BOM header and include the master data items we created in this course. Then test your work area by loading all the data you created this week.

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1.

Change your work area, PLM##, to focus on the BOM header. Include all master items you created this week.

2.

Use your new work area to load all the master data you created this week. What is the difference between your work area and the P_ALLES work area we used previously?

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Solution 27: Create a Work Area Task 1: Create a work area with focus on the BOM header and use it to make a change in a BOM. 1.

2.

Create a work area called PLM## with focus on the BOM header. a)

In the IMG, choose Production → Basic Data → Engineering Workbench → Edit Working Areas or use transaction code OP77.

b)

Choose the New entries button.

c)

Enter PLM## as the name of your working area with description Work Area ##.

d)

In the Focus section, select BOM Header.

e)

In the Contained in Work Area section select BOM Header and choose Save.

Use your new work area to make a change to the quantity of component 30 of the BOM of T-F##. What is missing in the work area that prevents you from making this change? a)

From the main menu, choose Logistics → Production → Master Data → Engineering Workbench or use transaction code CEWB.

b)

Select your new PLM## working area and choose Continue.

c)

Enter T-F## as the material number.

d)

Choose the Load BOMs icon.

e)

Try to drill down to the item level in the BOM. The browser doesn’t let you, and the menu path Bills of Material → Items is greyed out.

f)

It is not possible to drill down to the item level because only headers were included in the work area.

Continued on next page

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Task 2: Change your work area to focus on the task list header and include task list header, operations, and material-routing assignments in the work area. Use you work area to assign BOM components to an operation on the routing. 1.

2.

Change your work area, PLM##, to focus on the task list header. Include task list header, operations, and material-routing assignments in the work area. a)

In the IMG, choose Production → Basic Data → Engineering Workbench → Edit Working Areas or use transaction code OP77.

b)

Select your work area, PLM##, and choose Details

c)

In the Focus section, select Header.

d)

In the Contained in Work Area section, select Operations and everything above it in the list will be automatically selected.

e)

Choose Save.

.

Use your new work area to assign material components of the BOM of T-F## to operations. What is missing in the work area to be able to make this change? a)

From the main menu, choose Logistics → Production → Master Data → Engineering Workbench or use transaction code CEWB.

b)

Select your new PLM## working area and choose Continue.

c)

Enter T-F## as the material number.

d)

Choose Load Task Lists and BOMs icon.

e)

Select a routing and choose Task Lists→ Component Assignments. Unfortunately, it is greyed out.

f)

It is not possible to drill down to the item level because BOM items were not included in the work area.

Continued on next page

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Task 3: Change your work area to focus on the BOM header and include the master data items we created in this course. Then test your work area by loading all the data you created this week. 1.

2.

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Change your work area, PLM##, to focus on the BOM header. Include all master items you created this week. a)

In the IMG, choose Production → Basic Data → Engineering Workbench → Edit Working Areas or use transaction code OP77.

b)

Select your work area, PLM##, and choose Details

c)

In the Focus section, select BOM Header.

d)

In the Contained in Work Area section, select BOM header, Sub-Item, Component Assignment,, Sub-Operations, PRT, Trigger Point, .

e)

Also in the Group Processing section select BOM and Task Lists.

f)

Choose Save.

.

Use your new work area to load all the master data you created this week. What is the difference between your work area and the P_ALLES work area we used previously? a)

From the main menu, choose Logistics → Production → Master Data → Engineering Workbench or use transaction code CEWB.

b)

Select your new PLM## working area and choose Continue.

c)

Select the Additional Selection Criteria icon .

d)

On the Header tab page, choose More Selection Criteria

e)

In the Explorer window that appears, expand the Material to BOM Link folder by clicking the triangle to the left of it.

f)

Select Created by and choose Copy Selected Items icon.

g)

Complete the field with your user ID and choose Save.

h)

Choose Load BOMs and Task Lists .

i)

Compare this view to the P_ALLES view we used previously.

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Lesson Summary You should now be able to: • Create a work area • Explain the effect of the work area focus • Explain the effect of objects contained in the work area

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Introduction to the PLM Web User Interface Lesson Duration: 30 Minutes

Lesson Overview In this lesson we will look at another alternative interface that can be used for master data maintenance to make it easier for users to work in the SAP ECC system.

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

Explain the use of the PLM Web UI. Navigate in the PLM WEB UI Maintain master data objects using the PLM Web UI

The PLM Web UI was added as an initiative in PLM 7.0 and is included in EhP4. It is intended for collaborative environments to control access by various users. The table locks are like standard SAP functionality and not like the EWB. This is only an introduction which focuses on master data maintenance. The specific functionality for DMS, iPPE, and ECM is introduced in PLM100 and covered in more detail in the respective courses.

Business Example Your business collaborates on projects to develop new products and improve existing products with both users from a subsidiary and with external users. You need to give the project personnel access to master data that only pertains to the specific project to which they are assigned but you do not want to give them access to all master data objects. Also since not everyone on the project has the SAP GUI installed, you need an alternative way to collaborate effectively with your project personnel.

Introduction to the PLM Web User Interface The PLM Web User Interface works very well in collaborative environments where you collaborate with internal users of a subsidiary company or with external users to develop new products or improve existing products. Using this new interface you can give project members access to only the project data to which they are assigned. This creates a security level for collaboration that can

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be managed at the project level. And since the PLM Web UI is a web browser based interface, members of the project team can access and maintain master data objects in your ECC System using only a web browser. You can manage the master data objects relevant to SAP PLM on the Web user interface (Web UI) of SAP Product Lifecycle Management (SAP PLM) including the following: • • • • •

Material Master Records BOM Document Change master record Classification (Tab pages for classes and characteristics are integrated in the Web UIs of the objects name above.)

Other applications are also available.

Figure 161: Collaboration Internal

You can control access to information on the Web UI at context, user, or role level. For example, not all users will be allowed to call up all material BOMs even though they have general authorization to display material BOMs. You can use access control contexts (ACC) and access control lists (ACL) to tailor user access to the objects on the PLM Web UI to your requirements.

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Figure 162: Collaboration External

In particular, the Web UI supports you when working with partner enterprises via the Internet. You can give external users Web access to the data in the PLM back-end system without allowing them direct access to the back-end system. The Web UI can be decoupled from the back-end system and installed in a demilitarized zone (DMZ) outside your corporate firewall.

Access Control Management The access authorization concept of this component supports business use cases where a user freely navigates in the SAP PLM system. The users’ access authorizations determine the objects that they can find and work with. These scenarios can occur when employees of different subsidiaries are working in the same SAP PLM system, for example, if external employees share the same office with internal employees (in an integrated external design team), or trusted external parties (for example, a supplier, or an engineering service provider) access the SAP PLM system using the internet. Collaboration within the intranet of a company Due to globalization more and more companies are working with subsidiaries or they work with engineers who are employed by other companies. In some cases the external engineers work in the same office as the internal employees and access data through the company’s intranet. This is also true when subsidiaries are connected to the company’s data through a virtual private network (VPN). Even in cases when only internal employees are working with an SAP PLM system,

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they should not have access to all data in the system. For example, an automotive company segregates data that is solely relevant for the Formula One department from internal employees who have no Formula One-related tasks. Moreover, business objects in a system (like a material) can be the responsibility of a certain team, project or department. If a user wants to change a specific material, the system checks whether the material belongs to the user’s area of responsibility. If not, the system prevents the user from changing the material. In all cases, both the internal and external engineers need access to the information that is necessary for their work. However, due to the protection of intellectual property they should not have access to information that is not relevant for their work. Protection of intellectual property applies in particular to external employees and to employees of subsidiaries that have a lower level of trustworthiness. We provide a solution for this requirement with this component.

Figure 163: ACC - Direct Access

The concept of Access Control Contexts (ACCs) offers the possibility to define a context which represents a department or project and contains data (business objects such as documents, materials, bill of materials and change numbers) relevant for the department or project. Furthermore a set of specific roles which define authorized activities for all relevant business objects are assigned to this context. By assigning users to a context role it possible to grant access only to the relevant objects in the PLM-backend. All other information will not even be visible to your partner because it is not assigned to the specific context or the activity to display/process the information is not granted by context roles. This

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approach allows for collaboration with trusted external partners in addition to proven approach with SAP cFolders an alternative way of collaboration with no need to replicate data. In addition the access to data in the PLM backend for internal employees or external employees working in the intranet can be controlled. Collaboration with business partners accessing data from the extranet In other cases, the external engineers work in remote locations and use the internet to access data. The same considerations regarding data security apply as above, but in addition the level of trust determines what type of software solution we recommend for collaboration with external parties. When the level of trust is low, it makes sense that external parties access only copies of the original objects, as these external parties should not be able to access the company’s intranet. The copies reside in another system than the originals, which are stored in the SAP PLM back-end system. We offer Collaboration Folders (cFolders) to support this approach. For more information, see Design Collaboration with cFolders. Replication of the relevant data from one system to a collaboration system and reconciliation of the collaboration data back into the original system result in significant efforts. These efforts are only justified by the low level of trust. Therefore, when the level of trust is high and the data volume is high, the alternative method is preferable: direct controlled access to the original data in the SAP PLM system.

Figure 164: ACC - Indirect Access

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Internal employees can access directly all relevant data in the PLM backend. The access to this information (e.g.: materials, documents, etc.) is controlled by the classic SAP authorization concept. To collaborate with your partner your company uses SAP cFolders. All relevant information is replicated to cFolders so that the external engineers can access and work with these documents. On a regular basis all information has to be reconciled to the PLM backend so all parties have a consistent data basis. Due to this principle it becomes obvious that the replication and reconciliation of the relevant data cause significant efforts. These efforts are justified only when the level of trust is low so that you do not allow your partners access to the PLM backend directly Direct controlled access to the original data in the SAP PLM system (but only to data that is relevant for the actual work) is the recommended approach when collaborating with trusted external parties. We provide a solution for this requirement with this component.

Control Center The control center is the central initial screen on the Web UI of SAP PLM and provides an overview of the objects of different PLM object types you are working on. It also provides central access to these objects. The information displayed in the object lists presents the information from the different work centers in consolidated form. You can also specify default values for the navigation.

Figure 165: PLM Control Center

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To access the control center, choose Work Overview in the SAP PLM UI. The fields which are to appear on the Generic tab page of the Edit Work Environment window can be specified in Customizing. If you do not make any settings in Customizing, the settings supplied with the standard system apply. The following sections appear on the Work Overview screen page: • • •

•

Work Environment - This is where you specify settings and default values for the Control Center. Search - You use the search to find individual objects that are not listed and that you have not yet specified as favorites My Contexts - This screen area contains the list of access control contexts to which you are assigned. Depending on your role, you may also display the individual access control contexts and edit them . My Objects - This screen area contains lists of your object favorites and the objects that you recently accessed and changed. You can display or change all objects directly or display them in the Object Navigator by choosing the relevant pushbutton on the tab pages. When you click an object, the system opens it in edit mode.

In the work environment, you can specify default values for certain key fields of objects to which you want to navigate. The following fields are displayed in the Work Environment screen area and by choosing Edit Work Environment, you can specify the values for these fields on the Specific tab page •

• •

Change Number Key Date - The key date specifies the date for which the object is displayed. You can specify whether the key date is the current date, a date you entered, or the valid-from date of the specified change number. Plant - If you are using bills of material, the bill of material is displayed in this plant. If you do not enter a plant, the group BOM applies. Context - Specifies the access control context, that is, the area whose business objects can only be accessed by users with a corresponding context role.

Depending on your Customizing settings, you can specify more default values, for example the (BOM) usage, on the Generic tab page of the Edit Work Environment window and you can specify which fields appear on this tab page. You can personalize the My Objects screen area and hide the tab pages. To show the tab pages again, you have to define a new query. You can also add your own tab page using a customer-specific enhancement. There is no limit on the number of favorites that can be displayed. You can change the query for the last-accessed and recently-changed objects to specify how many objects the system should display. You can use the transaction links to call transactions for creating, displaying, and changing different PLM objects.

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Demonstration: PLM Web UI Navigation and Search Function Purpose To show the PLM Web UI accessed through the portal. You will want to show students some navigation and the search function. The search function is only available if the PLM Web UI is access through the portal or NetWeaver Business Client. If students access the functionality through the WebDynPro transactions it will not be available to them.

System Data System: ZTE Client: 800 User ID: PLM-## Password: initial Set up instructions: You may want to change the language to English in SU01 for the user ID that you use. 1. Access the PLM Web UI using the provided transaction or http://portal-zte.wdf.sap.corp:50000/irj/portal. This may work by substituting your system ID for zte in the url. Log in with one of the above logons.

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2.

Click on the PLM Expert tab. Point out the different sections. Since your user ID is not assigned to any context both the My Context and the My Objects sections are blank.

3.

In the Work Environment section, click the Edit Work Environment button. Enter ECN## in the Change Number field and 1000 in the Plant field and click Save.

4.

In the Search section, click on Advanced Search. A new dialog box will open and you can enter your User ID in the Created By field to select all objects that you have created. Click Go to retrieve those objects.

5.

Select all the objects on the results list and choose Additional Functions -> Add to Favorites.

6.

When you close the Search window, click Refresh at the bottom of the PLM Favorites tab. The complete list of objects should now appear on that tab.

7.

You can access any of the objects by simply clicking on them. The work center for that object will appear with the object information.

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Work Center You use the work centers for the individual objects in SAP Product Lifecycle Management (SAP PLM) to display predefined object lists with object-specific information and customer-defined worklists for a particular PLM object type. The following work centers are available on the SAP PLM Web UI and can be selected depending on your role: • • • • •

Materials Material BOMs Documents Change Management Object Access (access control contexts)

The different work centers have some functions and screen areas in common. In addition, the work centers for documents and access control contexts have some special features. The following functions and screen areas are available in all work centers:

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Figure 166: PLM Work Center

•

•

•

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My Materials (or other objects) - The system displays your favorites as well as the most recently accessed and changed objects, the same as in the control center. The difference is that the lists in the work center only contain objects of the object type, for which the work center is defined. The system also displays object-specific information, such as base unit of measure, material type, or revision level, in addition to general information. Personal Object Worklist for Materials (or other objects) - You can define your own queries, that is, your own worklist in this screen area, which is supplied as an empty screen area by SAP. You can change and rename the empty query or you can define a new query. For example, this enables you to create a worklist which lists all material BOMs with the status Locked. You can use the Personalize link to delete or rename the tab pages. You can display or change the objects in the list by choosing the appropriate pushbutton. Search and Transaction Links - You use the search to find individual objects that are not listed and that you have not yet specified as favorites. You can use the transaction links to call transactions for creating, displaying, and changing of the object type of the relevant work center.

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Demonstration: Using the Work Center to Change a BOM with ECM Purpose This is to show students how to do the exercise for this lesson. We will use the ECM number you created earlier in the course and replace a component. In 2 months when you replace the casing you also want to upgrade the screws at the same time. So component 100-130 will be replaced by T-T3##.

System Data System: zte Client: 800 User ID: PLM-## Password: initial Set up instructions: You may want to change the language to English in SU01 for the user ID that you use. 1. From the Control Center, click on Change Material BOM on the left side. 2.

If you did the previous demo then plant 1000 and change number ECN## should default. If not, provide that info, enter material T-F##, BOM Usage Production, and click Start.

3.

Replace component 100-130 with T-T3##. the valid from date should change according to the ECM validity date.

4.

Click Save and Close.

The PLM Object Navigator The Object Navigator is a flexible display tool, which provides navigation help for complex object relations on an integrated user interface. The objects involved can be related to each other across system boundaries. For individual roles, you can control access to objects and the composition of the relations involved. The Object Navigator relationships can be configured in customizing to make it easier for users to locate the information. This is a display only view of the data but can be invaluable at locating the information needed.

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Figure 167: PLM Object Navigator - Center for User Interaction

Figure 168:

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The starting point of the object navigator is the central object that you load in the object navigator. The system displays the objects that are related to the central object in the views of the object navigator. You can display a complex structure using the relations that you have defined for a view in the object navigator Customizing.

Figure 169: PLM Object Navigator

In the object navigator, you can do the following: • • • • •

Display specific object data (attributes) for the central object and the related objects Display relations between objects Navigate along the breadcrumb trail to related objects or to the central object Navigate from the central object to related objects via Structure links Navigate to the object-type-specific applications, such as the display or change modes

Product Centric View You can use PCV to easily retrieve product-related information originating from various internal and external data sources. PCV provides analytical applications that are embedded and operate within the context of the business application you are working in. PCV enables you to effectively use analytical capabilities within the context of business objects, such as materials. The PCV provides one central location to access all data relating to a product.

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Figure 170: Product Centric View

PCV comes delivered with predefined business content for the analysis of materials. You can enhance this standard content and configure PCV for your own business needs. Furthermore, you can monitor the configuration and use of PCV. PCV consists of four components: • • •

•

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User Interface - The software layer of PCV that contains visual presentation. Query Management - The software layer of PCV that processes queries. Search Integration - The software layer of PCV that contains the integration of data source searches in PCV. The data is provided to query management in a unique structure. Foundation, Monitoring - The software layer of PCV that contains basic functions for all layers.

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Figure 171: Product Centric View - Side Panel

The side panel contains product data in various forms. Tables, charts, reports of various kinds and from various sources can be embedded for quick access to the data needed for decision making. The types of data and reports can be user specific or role specific. You can use this function to display additional contextual information for a central object or selected object. The side panel is not intended for displaying object details. It provides context-sensitive analytics and supplementary information. The context is defined by the main application, SAP Product Lifecycle Management (SAP PLM). You can access the side panel from the work center of the SAP Product Lifecycle Management Web UI, by choosing Side Panel. The side panel contains the following tab pages: •

•

•

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Previews - Displays previews of query views that you have defined. You can enlarge the query views that the previews represent in the view area for further analysis or editing. Query Views - Displays the list of query views you have defined for the specific business object you are working with, as well as the SAP predefined query views for the specific business object. Dashboards - Displays a list of predefined dashboards. A dashboard displays product-related information in a single page, allowing you to compare different data, and easily share information. A dashboard can display a maximum of nine query views.

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Figure 172: Product Dashboard

The data charts and reports can be organized in the Product Dashboard. You can use this function to get a comprehensive overview on product-related information. You can display as many as nine query views, which enables you to analyze and compare data. To access the list of dashboards available for the business object you are working with, choose the Dashboards tab page in the side panel and click on the name of the dashboard.

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Exercise 28: Using the PLM Web User Interface Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Navigate in the PLM Web User Interface • Use the search and favorites features of the PLM Web UI • Change a BOM using the PLM Web UI

Business Example Navigate in the PLM WEB UI.

Task 1: Navigate in the PLM Web User Interface. 1.

Navigate to the PLM WEB UI using the role based menu, SAP_CA_PLM_DESIGNER and logon using the data below. Set your work environment to default your Engineering Change Number ECN##, plant 1000, and Active Context GROUP##. Client

800

User

PLM-##

Password

(the password you changed it to in Exercise 1)

Language

EN (or your choice)

Task 2: You want to be sure that you begin using the new updated screws at the same time as you begin using the new casing.

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1.

In the material BOM for material T-F## in plant 1000, the casing has already been replaced with a new material to begin in 2 months. We also want to change the screws to an updated version at the same time as we make the change to the casing. Use the same ECN## in the PLM Web UI to replace component 100-130 with T-T3##.

2.

Display the material master record in the PLM WEB UI.

3.

Display the BOM for material T-F1##Use the PLM WEB UI

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Solution 28: Using the PLM Web User Interface Task 1: Navigate in the PLM Web User Interface. 1.

Navigate to the PLM WEB UI using the role based menu, SAP_CA_PLM_DESIGNER and logon using the data below. Set your work environment to default your Engineering Change Number ECN##, plant 1000, and Active Context GROUP##. Client

800

User

PLM-##

Password

(the password you changed it to in Exercise 1)

Language

EN (or your choice)

a)

In the role based menu SAP_CA_PLM_DESIGNER use the following menu path PLMWebUI → Internet NWBC.

b)

Enter the above information from the table and click logon.

c)

In the Work Environment section, click the Edit Work Environment button. Enter ECN## in the Change Number field, 1000 in the Plant field, GROUP## in the Active Context field, and click Save.

d)

These defaults should now be visible in the work environment section.

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Task 2: You want to be sure that you begin using the new updated screws at the same time as you begin using the new casing. 1.

2.

3.

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In the material BOM for material T-F## in plant 1000, the casing has already been replaced with a new material to begin in 2 months. We also want to change the screws to an updated version at the same time as we make the change to the casing. Use the same ECN## in the PLM Web UI to replace component 100-130 with T-T3##. a)

From the Work Overview screen, click on Change Material BOM in the left panel.

b)

If you did the previous demo then plant 1000 and change number ECN## should default. If not, provide that info, enter material T-F##, BOM Usage Production, and click Start.

c)

Replace component 100-130 with T-T3##. the valid from date should change according to the ECM validity date.

d)

Click Save and Close.

Display the material master record in the PLM WEB UI. a)

From the Work Overview screen select Display material in the left panel.

b)

Enter material T-F1##, be sure to delete the ECN number ECN##, and click Start.

c)

Notice the document that is assigned to the material master is displayed on the screen. Click Close to exit back to the Work Overview screen.

Display the BOM for material T-F1##Use the PLM WEB UI a)

From the Work Overview screen select Display material BOM in the left panel.

b)

Enter material T-F1##, plant 1000, Usage Production, be sure to delete the ECN number ECN##, and click Start.

c)

In order to check up on sales and quality information use the side panel viewer by clicking Side Panel in the very upper right of the screen.

d)

The quality, sales, and purchasing data appears. They are empty because no data has been collected yet.

e)

Click Close to return to the Work Overview screen and exit the PLM WEB UI.

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Lesson Summary You should now be able to: • Explain the use of the PLM Web UI. • Navigate in the PLM WEB UI • Maintain master data objects using the PLM Web UI

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Unit Summary

Unit Summary You should now be able to: • Use the engineering workbench for routing maintenance • Use the EWB browser functions • Navigate in the engineering workbench • Create a work area • Explain the effect of the work area focus • Explain the effect of objects contained in the work area • Explain the use of the PLM Web UI. • Navigate in the PLM WEB UI • Maintain master data objects using the PLM Web UI

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Unit Summary

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Unit 11 Appendix

483

These configuration topics are rarely (i. e. only initially) used in the ECC system. In order to add additional topics of new functionality, this information has been moved to the appendix. It is optional and should only be covered in someone in the class is very interested. Students can use these lessons for self study, if required.

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

Describe the process of influencing the field characteristics of the material master Describe Process of configuring the screen layout of the material master Set up a customized material master in Customizing Test the settings by creating a material master Describe the configuration activities surrounding the BOM header Describe the configuration activities surrounding the BOM items Define default values for work centers Explain the configuration settings regarding work centers Create and test work center formulas Define system settings for routings

Unit Contents Lesson: Configuration of the Material Master ...............................551 Procedure: Setting Up Screen Sequences .............................562 Exercise 29: Material Types, Field Control and Material Status......567 Lesson: Configuration of the Bill of Material.................................574 Exercise 30: Bill of Material Configuration ..............................585 Lesson: Configuring the Work Center .......................................590

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Exercise 31: Work Center Category and Field Selection Control, Default Work Center (Optional) ...........................................609 Exercise 32: Optional: Work Center Formulas .........................615 Lesson: Configuring the Routing..............................................622

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Lesson: 484

Lesson: Configuration of the Material Master

Configuration of the Material Master Lesson Duration: 60 Minutes

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

Screen sequence Logical screens Subscreens Influencing factors

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

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

Discuss the functions and importance of Material Type decisions. Configuring screen sequences and customized material master screens is fairly uncommon. Suggestion is to focus on the configuration of Material type, field selection and Material Status.

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

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Configuration Sequence for Material Master Records

Figure 173: Configuration Sequence for Material Master Records

The abbreviations in the graphic have the following meanings: • • •

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

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

552

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

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Lesson: Configuration of the Material Master

Figure 174: Field Selection Procedure

You can find out the table name of a field by using the technical information in the F1 help. In Customizing, you can use the table name to help you find the appropriate field selection group.

Figure 175: Field Selection - Field Selection Group

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

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The field selection option applies to all the fields in the field selection group (for example, all the fields are required fields). Hint: Always check first which fields have been assigned to a field selection group. Do not make changes without consulting the affected department.

Figure 176: Field Selection - Influencing Factor

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

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Figure 177: Field Selection - Link Rules

Field selection in a material master transaction is generally determined by several control strings. The entries of all the control strings for the relevant transaction are linked to one another. The link rules shown above determine which fields are selected for each group of material master fields. In order of priority, the signs mean: - Hide * Display + Required entry . Optional entry Field Selection: Procedure Field Selection: Field Selection Group (OMSR and OMS9) Show the possible settings in Customizing and the detailed procedure, and add the newly created field reference to material type MM##, which you created previously. ... Logistics – General →Material master →Field selection: Assign fields to field selection groups … Maintain field selection for data screens … Hint: You can use two transactions for maintaining the field selection (as of ECC 4.0): 1. 2.

Assign fields to field selection groups (OMSR) and Maintain field selection for data screens (OMS9)

Both settings can be maintained from transaction Assign fields to field selection groups (OMSR).

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You should demonstrate the detailed procedure – it is also important to point out that these settings are references. This means that a subsequent change affects all existing objects. 1.

2. 3.

Which field is to be controlled and how? Use the F1 help to find the name of the field, and define how to control it. (Hide - Display - Required or optional entry) Find the corresponding field reference or create a new field reference with a template. Control the field selection group you have just determined accordingly. Caution: You always control the whole field selection group. This means that you must consult with the affected user department.

4.

Assign the new field reference to the new material type (MM##) and test the field control by changing the new material master record.

Field Selection: Influencing Factors and List of Influencing Factors The field selection references can be assigned in different control tables: 1) Material type (OMS2) 2) Plant (OMSA) 3) Industries (OMS3) Hint: In addition, the program determines the: 4) Transaction field reference and 5) Procurement type field reference . Caution: If you also want to use transaction and procurement type to control, do not delete these field references. For example: E means in-house production, MM01 means create material master (general) immediately. Field Selection: Link Rules Explain the link rules, because 1-several field references are always linked. The highest priority is determined when linking. This means the field references are read per field group and the highest priority becomes effective. The field references are linked with or –> the highest priority (lowest number) that appears is set. Order of priority – whereby the lowest number represents the highest priority (each priority is represented internally with an alphanumeric character):

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1)

Hide

-

(Minus sign)

2)

Display

*

(Multiplication sign)

3)

Required entry

+

(Plus sign)

4)

Optional entry

.

(Period)

Demonstration for the Field Selection Change material master record T-F1## and, in the basic data, use the F1 help, then technical information to display the names of the two fields: Old material number: MARA-BISMT Material status (cross-plant): MARA-MSTAE 
Both tables and fields names are in the technical information in the group box: Field description for batch input. Call transaction OMSR. Customizing→ Logistics – General →Material master →Field selection: Assign fields to field selection groups In the Sort and position group box, choose the pushbutton Field name (position on field name). Enter the field name for the old material number (MARA-BISMT). The Sel.Group column contains the corresponding field selection group = 11. Repeat this for the field Material status (cross-plant) (MARA-MSTAE) –> Field selection group = 155. Hint: It is always the field selection group that you control – not the individual field. The old material number (MARA-BISMT) contains no further fields in field selection group 11. The cross-plant material status (MARA-MSTAE) in field selection group 155 also contains the Date field, from which the cross-plant material status is valid (MARA-MSTDE). Demonstration with the field: Planned delivery time in days (EINE-APLFZ) in field selection group 190 – example showing that not just one field is controlled. The setting (control) of field selection groups can be done as follows: 1.

2.

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Next to column Sel. Group, you can go directly to field selection maintenance (direct link between transaction OMSR and OMS9) without leaving transaction OMSR. Exit transaction Assign Fields to Field Selection Groups (OMSR) and start transaction Maintain Field Selection for Data Screens (OMS9).

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Advantage of solution 1: Since you select the field you want to change first, this field selection group is displayed immediately. Copy (F6) field selection reference FERT to your new field reference Z00 and set the fields as follows: Old material number

MARA-BISMT

Required entry

Material status (cross-plant)

MARA-MSTAE

Required entry

Assign the new field reference Z00 to your material type MM00 and create a new material with your new material type T-A00.

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

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

Figure 178: Customized Material Master (1)

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

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Each logical screen consists of several related field groups. In ECC these are referred to as subscreens. The fields assigned to each screen module cannot be changed in Customizing. In Customizing for the material master, you can: • • • • • • •

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

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

Figure 179: Screen Sequence

A screen sequence consists of logical screens (views) and secondary screens. The sequence of the screens can be specified for each screen sequence. You can define a screen sequence to suit your requirements.

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Figure 180: Subscreens

A logical screen (view) consists of several screen modules. It consists of a subscreen container where you can enter several subscreens (maximum of 6). Standard screen modules (SAPLMGDI) have exactly one frame that can contain up to 10 lines and they have exactly 83 columns. You are free to choose the sequence of the screen modules. You can vary the number of subscreens for each logical screen. Subscreens from different logical screens can be grouped together on one screen. The maintenance status of the screen module fields must be the same as the maintenance status of the logical screen. You may have to extend the status of the logical screen in Customizing. Changes to a logical screen are saved in the screen sequence that is changed. This means that if you change the structure of MRP 1 in sequence 99, this change is only effective in sequence 99.

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Figure 181: Topic Summary: Customized Material Master

When creating your own logical screens we recommend that you use the standard subscreens that are already available. You will need your own subscreens if different field groups or new fields are required. To create your own subscreens, copy standard program SAPLMGD1 to its own function group (for instructions, see the IMG). Then create the required subscreen in the new function group. Append structures have been defined in DDIC for including your own fields. You can only include fields from user-specific tables and user-specific subscreen containers in program SAPLMGMM by using modifications. Before you configure your own material master record dialogs, be sure to read the IMG.

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Setting Up Screen Sequences 492

1.

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

2.

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

3.

In the dialog structure for maintaining screen sequences, data screens, and subscreens, copy screen sequence 21 with all its dependent entries to your new screen sequence Y#. Save the screen sequence. In the Screen Sequences view, select 21. Choose Copy As (= F6). Y# screen sequence group ## Choose Enter. Wait! Approximately 3000 dependent objects are copied. Choose Save.

4.

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

5.

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

Material number

2502

Control repetitive manufacturing

2504

Discontinuation control.

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

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

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

7.

Change your screen sequence ## so that the data screens appear in the following sequence: 1. Screen

Basic data

2. Screen

MRP 4

3. Screen

Work scheduling

4. Screen

Storage location stock

5. Screen

Classification

The rest of the sequence following these data screens should remain unchanged. Under Maintain Order of Main and Additional Screens, select your screen sequence number and click the Details icon or double-click on the new screen sequence. Change the order according to the task. MRP 4

140 –> 11

Work scheduling

160 –> 12

Storage location stock

280 –> 13

Classification

30 –> 14

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

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

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In Screen sequences for users / material types / transactions /
assign industry sectors, display the step Screen reference user. Maintain a new entry. Use the user name that you used to log on to the system and assign an abbreviation to it.
 For example, Y# (the same abbreviation as the new screen sequence)
. Choose Save. Under Controlling screen sequence, create a new string (New entries) or copy the existing control string with the screen sequence 21 as a template, and enter the following values: SRef: trans.

01

ScrRef.User

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


ScrRef. matl type

*


ScrRef. industry

*

Scr.sq

The screen sequence number you created (input help)

Save your changes. 9.

Check your settings by displaying material master T-F1##. Check your settings as described in the exercise.

General Check Tables for the Material Master Record

Figure 182: Other Check Tables for the Material Master Record

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

General Check Tables for the Material Master Record Show the Customizing directory where the check tables are maintained. Point out that not all check tables are hard check tables. For example, the table for basic materials is not a hard check table – you can also enter values that are not maintained in Customizing. The material group, for example, is a hard check table → values must be maintained in Customizing first: Customizing → Logistics – General →Settings for key fields: Define material groups (Transaction:OMSF)

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Lesson: Configuration of the Material Master

Exercise 29: Material Types, Field Control and Material Status Exercise Duration: 30 Minutes

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

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

Task 1: Add a new material type MA## (## = group number). 1.

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

2.

Note the following specifications for the new material type: - External and internal purchase orders are allowed. - Externally assigned material numbers should not be checked against a number range. - Cost estimate with quantity structure (BOM, routing) is allowed. For materials of this material type, the following views are allowed to be maintained: Work scheduling, accounting, classification, MRP, purchasing, costing, basic data, storage, plant stocks, and storage location stocks. In all plants (valuation areas) the quantities and values for materials of this material type should be updated. The valuation of all materials of this material type should be binding (that means not changeable) according to the valuation procedure moving average price. Continued on next page

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

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

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

Field name complete

Old material number

(MARA-BISMT)

Material status (cross-plant)

(MARA-MSTAE)

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

568

1.

To which field selection group do these fields belong?

2.

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

3.

What other fields belong to these groups?

4.

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

5.

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

6.

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

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Solution 29: Material Types, Field Control and Material Status Task 1: Add a new material type MA## (## = group number). 1.

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

Creating a new material type: From the SAP Easy Access screen, choose Tools→ Customizing→ IMG → Edit project (SPRO). Choose Display SAP Reference IMG (F5). Choose Logistics general → Material master →Basic settings → Material types → Define attributes of material types. Select material type FERT. Click Copy (F6).

2.

Note the following specifications for the new material type: - External and internal purchase orders are allowed. - Externally assigned material numbers should not be checked against a number range. - Cost estimate with quantity structure (BOM, routing) is allowed. For materials of this material type, the following views are allowed to be maintained: Work scheduling, accounting, classification, MRP, purchasing, costing, basic data, storage, plant stocks, and storage location stocks. In all plants (valuation areas) the quantities and values for materials of this material type should be updated.

Continued on next page

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

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

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

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

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

In Customizing, choose Logistics general → Material master → Basic settings → Material types → Define number range for each material type. Choose Change groups (F6). Your material type should already be assigned to group 1 (the same as FERT). If not, select material type MA##, select the group to which material type FERT belongs and choose Assign element / group (F5). You may want to display the assigned number ranges here, too: choose Maintain (Shift+F5).

Continued on next page

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

Field name complete

Old material number

(MARA-BISMT)

Material status (cross-plant)

(MARA-MSTAE)

You can see the data for the individual fields that you want to change by using the field help (F1 or Help icon) and choosing the Technical Information button or the Technical Information icon. 1.

To which field selection group do these fields belong? a)

Setting fields as required entry: First you determine the numbers of the field selection groups. For this, choose Logistics general → Material master → Field selection: Assign fields to field selection groups in Customizing. Field selection groups (search by field name) MARA-BISMT: 11 MARA-MSTAE: 155

2.

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

The contents of the fields is copied on creation, because the reference indicator (default field content) is set. Select the field and click on Detail or double-click on the 
field names.

3.

What other fields belong to these groups? a)

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

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4.

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

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

b)

Copy a field selection reference with the new name Z## and set it up so that the fields named above are displayed as required entries. As a template, use the field selection reference for the finished product FERT. Select the line FERT and copy it to Z## (choose Edit → Copy as, or corresponding pushbutton, or F6). Name

Z##

Line 11

Required entry

Line 155

Required entry

Enter and save. 5.

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

Assign the field selection reference Z## to the material type MA##, while you assign the field selection Z## to the material type. In Customizing, choose Logistics general → Material master → Basic settings → Material Types → Define attributes of material types and then Change. The field reference is Z## instead of FERT.

6.

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

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

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

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Configuration of the Bill of Material Lesson Duration: 30 Minutes

Lesson Overview This lesson discusses the detailed configuration of the bill of material.

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

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

Discuss the various config options for BOM’s.

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

The BOM Header: Defining Modification Parameters You can do the following by making the corresponding settings in the modification parameters: • • • •

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

In the group box for validity, engineering change management (history requirement) for bills of material is defined. The low date setting means that the BOM validity is set to the earliest processing date when it is created by the

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system, that is, 01.01.1900. The low date cannot be changed. The valid-from date is a default value and can be changed by the user. If the low date is not activated (checkbox blank), the system proposes today’s date as the valid-from date. The technical types multiple BOM and variant BOM can be deactivated. In other words, no maintenance of bills of technical BOM types M and V is possible. In BOM items, you can use the explosion type of a BOM item to display by validity and define which text is displayed for a variable-size item. In the general settings, the base unit of measure is defined for BOM headers of special BOM categories, such as equipment BOM and document structure, and for special item categories. In addition, you can activate the CAD interface for bills of material (material BOMs only). Define Modification Parameters Show the possible settings in Customizing (OS27). Here, focus on the following: • •

Settings for ECM (first black apart from “low data”, “header”, “handling deletion flag”, for this “item explosion type”) Switching off technical types

BOM Default Settings Default values for the BOM header and settings for variable-size items are defined in Customizing: • • •

Base quantity for bill of material BOM status Unit of measure for size and number of variable-size items

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

Item increment Item category Material provision indicator Various BOM reporting options

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

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BOM Default Settings Show the possible settings in Customizing General default values (OS28): ... Customizing for Bills of Material → Control Data … User-Specific Default Values (OS29): ... Customizing BOMs → or in SAP Easy Access Menu ... → ... BOMs → Environment → Current Settings or in CS01 or CS02 initial screen Settings → Current Settings Hint: Change the user-specific default values for “DUMMY” so that they are very different from the settings for the exercise. (For example, delete all item categories)

Configuration Sequence BOMs, BOM Status, BOM Item Status The abbreviations in the graphic have the following meanings: M = Mandatory activity (must) O = Optional activity (optional) D = Default available for activity (default)

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Figure 183: Sequence for Customizing Bills of Material

Hint: 
When defining the BOM usage, the next step must be checking and maintaining the settings for default values for item status. At BOM header level, the department or person responsible and the history requirement for bills of material can be defined. When you process a bill of material with history requirement activated an additional authorization object is checked (C_STUE_NOH). If this authorization is assigned to a user, the user can change bills of material that have a history requirement without a change master record. The object types for BOM items may not be changed. The user-specific settings can be defined in Customizing for each user – with a high administrative overhead – or each user maintains their own user-specific settings in the master data functions for bills of material.

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Figure 184: BOM Status and BOM Item Status

The BOM status controls BOM processing in different application areas. When you configure your system in Customizing under Bill of Material → Define BOM Status, you define the statuses for different indicators that allow or disallow BOM processing.
 Examples: BOM A: A BOM with status 1 can be exploded in MRP and released for a planned order. BOM B: A BOM with status 2 cannot be exploded in MRP or released for a planned order. When you configure your system in Customizing (Bill of Material → BOM usage → Define BOM usages), you define which item statuses are allowed or disallowed for each BOM usage (general setting is valid for all items). Fine-tuned control is defined for each individual item. You can define item status fields as required, optional, or disallowed for a specific application area in your company. Hint: 
When defining the BOM usage, the next step must be checking and maintaining the settings for default values for item status.

Sequence for Customizing Bills of Material The points listed here are covered in detail in the following slides. The Customizing settings that are delivered are adequate for a substantial range of purposes. Do not spend time on the difference between D and K at this point. BOM Status and BOM Item Status

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BOM status: • • •

Here you might want to create a status with partial release Distribution lock for ALE Status 3 – Show history requirement (corresponding Customizing item)

Focus on: BOM Usage Based on this: •

Permissible material types for bills of material

• •

– Priority 1 = Usage & material type specified – Priority 2 = Usage specified – Priority 3 = Material type specified – Priority 4 = Nothing specified Default values for item status Copy default for item status

Demonstration of BOM Status, BOM Usage, and Item Status Show all the Customizing tables and make entries (optional). Hint: Change the Material Types Allowed for BOM Header so that the existing entries for specified BOM usage are deleted and replaced by the line: –>

*

*

+

. The restriction * INTR - is effective only if you do this. And the exercise only works if you do this.

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Alternative Determination

Figure 185: Alternative Determination

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

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

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

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Alternative Determination Explain: • • • •

Order of priority (mention that this is similar in routings) BOM applications Alternative determination for multiple BOMs Using one or two examples, alternative determination in related application areas (such as MRP and production)


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

Figure 186: Variable-Size Item with Formula for a Cylinder

Advantages: • •

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

Entering a formula for variable-size item calculation also enables complex calculations. In Customizing for item data, you can define your own formulas and assign them when creating new variable-size items.

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Caution: You can only use the variables ROMS1 – ROMS3, the constant pi, and the operators +, -, *, and /. If no formula key is entered, the following formula is used:
 • • •

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

Variable-Size Item / Item Category: R Variable-Size Item with Formula for a Cylinder Customizing Item Categories → next graphic Demonstrate the example: of a cylinder jacket and demonstrate the effect in a BOM item of category R with material 100-700.

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

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

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Figure 187: Item Categories

The item category controls: • • • • •

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

Item Categories Explain the Customizing steps: • • •

Define item categories Define object types Allowed material types for BOM items – – – –

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Priority 1 = Usage specified Priority 2 = Usage not specified & material type header specified Priority 3 = Usage not specified & material type header not specified & material type for item specified Priority 4 = Nothing specified

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On the item detail screen of BOM maintenance, show the tab pages: • •

Basic data Status/Long text

The participants should be familiar with the fields from course PLM110 – otherwise you may want to explain them briefly. (Caution: Time) 
Most of the fields are just flags. The other fields, except for the time and date fields, have Customizing settings. The tables can be shown in Customizing: For basic data: • • •

Distribution key Explosion type (Special procurement types)

For status/long text: • • • •

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Spare part indicator (purely selective indicator) Relevancy to sales (Relevancy to costing (all values here same meaning)) Material provision indicator

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Exercise 30: Bill of Material Configuration Exercise Duration: 15 Minutes

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

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

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

Effectivity (validity): Low date

2.

Technical type: Mult. BOM inactive

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

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

2.

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

Task 3: Define BOM usage. 1.

With usage Universal, which fields are required fields?

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

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1.

Which selection ID does the BOM application PP01 use?

2.

What is the order of priority of BOM usages?

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Solution 30: Bill of Material Configuration Task 1: When configuring bills of material by defining modification parameters, what is the effect if you change the modification parameters for BOMs by selecting the following checkboxes? 1.

Effectivity (validity): Low date a)

In Customizing choose Production → Basic data → Bill of material → Control data for bills of material→ Define modification parameters. Select validity. low date checkbox and press F1 (help). When BOMs are created or edited, the default date is the earliest processing date defined in the system: 01.01.1900.

2.

Technical type: Mult. BOM inactive a)

In Customizing choose Production → Basic data → Bill of material → Control data for bills of material→ Define modification parameters. Select technical type: multiple BOM inactive checkbox and press F1 (help). No multiple BOMs can be maintained in ECC; in other words, you cannot maintain alternatives for an existing bill of material.

Continued on next page

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

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

Set up the default values for a user in Customizing: choose Production → Basic data → Bill of material → Define user-specific settings. Caution: The same settings can be maintained by the user in the application for creating or changing a bill of material, provided that the user has the authorization for this. On the Change/Display Material BOM initial screen, choose Settings → Current settings. You can also get to the default values from the SAP Easy Access screen: choose Production → Master data → Bills of material → Environment → Current settings → User-specific settings (transaction OS29). Highlight the settings for an existing user. Click Copy As Replace existing user with your user ID. Choose Enter

2.

. Make the appropriate changes and choose Save.

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

Change the BOM T-F##. Choose Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change. Results: Item increments for all subsequent new items are set at intervals of 8. For material items, item category L is proposed; for document items, item category D is proposed.

Continued on next page

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Task 3: Define BOM usage. 1.

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

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

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

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

In Customizing, choose Production → Basic data → Bill of material → Alternative determination → Define applications. Results: PP01 uses selection ID 01.

2.

What is the order of priority of BOM usages? a)

In Customizing, choose Production → Basic data → Bill of material → Alternative determination → Define order of priority for BOM usages. The order of priority of the SelID 01 (selection ID) is: 1 (Production) 3 (Universal) 2 (Engineering/design) Example: If a material has several bills of material with different usages (one internal BOM number for each usage), the system searches for a production BOM first, then for a universal BOM, and then for an engineering/design BOM.

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Lesson Summary You should now be able to: • Describe the configuration activities surrounding the BOM header • Describe the configuration activities surrounding the BOM items

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Configuring the Work Center Lesson Duration: 45 Minutes

Lesson Overview In this lesson you will learn about the work center category, the field selection control, and the default work center. You will also learn how to configure scheduling, including the formulas, standard value keys, and the corresponding check tables.

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

Define default values for work centers Explain the configuration settings regarding work centers Create and test work center formulas

[Enter a description of what the instructor should discuss with the participants about the context of the lesson. ]

Business Example Your company has set some requirements that certain fields in the work center be made required entries in order to save a work center. As the project team member responsible for implementing work centers in SAP ERP, r. you must become familiar with how to configure the work center. Work Center Integration (Where can the operation be integrated at the work center?) Control key The control key controls for which activities an operation is permitted. The control key can be maintained in the work center and, provided the reference indicator is not set, can be overwritten in the operation. Showcase for the control key Control key as a required field for the process –> maybe show Control key can originate from work center –> maybe show in plan maintenance

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Show control key in work center incl. reference indicator Show the selection of the control key in work center maintenance or routing maintenance
 Show pushbutton Choose Show pushbutton Detailed information Show the control key in Customizing and explain. You do not need a new control key.

Work Center Work Center Data Like the material master, the work center is made up of several subscreens. This course explains only the subscreens that are most important for routing management. The most important fields are presented on the slide. The work center is plant specific and can be used in the routings if the subscreens have not all been maintained yet. However, for production orders, it is mandatory to assign cost centers and activity types. Demonstration for Creating Work Centers CR03 
For the slide on work center data, use work center 2050 /plant 1000 to explain the most important fields for maintaining operations. CR01 For work center DEMO12 /plant 1000, create the basic data screen only using work center category 0001. Briefly explain the structure and point out default values. Exit without saving.

Work Center Category The work center category is the central control element for work center maintenance.

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Figure 188: Configuring Work Centers: Work Center Category

You use the task list application to define which departments can use the work center. If you activate creation of change documents, you can trace changes to the work center. You can assign a user status profile to the work center category. To maintain a user status profile, use transaction BS02. You can also use the work center category to control the color in which a work center is shown in a hierarchy graphic. Field selection control lets you define, field-by-field, which fields are ready for input, display only, highlighted, or hidden. The order of the screens can be specified for each work center category by using screen sequence control. The default work center makes work center maintenance easier and can be defined per plant and work center category. Configuring Work Centers - Work Center Category Hint: A color can be assigned to each work center category for the hierarchy graphic (as of R/3 4.6). Demonstration for Creating Work Center Categories As in the exercise:

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Work center category

PL99

Description

Demo Category 99

Task list application

only P (=routing for production, standard routing)

Color

RED_8

To test this, create work center TEST99 using the new work center category. => maximum views no default values Fill mandatory fields only (name only) and assign work centerhierarchy 1000 (plant 1000) to work center 1100. And: Goto →Hierarchy →Hierarchy graphic Save.

Work Center Configuration: Screen Control You can define a separate screen sequence for each work center category. Several work center categories can use the same screen sequence.

Figure 189: Configuring Work Centers: Screen Control

The screen sequence controls which views are to appear in which order, and which views are required for checking the routing. The screen sequence always starts with the basic data. The basic data is always mandatory. All other screens can be selected as and when required, can be numbered and sorted in any order, and can be mandatory if you so decide.

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The structure of screens (for example, the subscreens) cannot be influenced by Customizing (as is possible for the material master record). Note: Mandatory data: This indicator is relevant to the check work center function in work center maintenance only. If you have not yet processed a screen of the work center and execute the Check work center function, you see one of the following messages: “Data is still to be maintained”, if the indicator for the screen is set. “Data should still be maintained”, if the indicator for the screen is not set.

Configuring Work Centers – Screen Control Use the demonstration to explain: "Obligatory data" see notes Demonstration of Screen Control Screen control for work center category PL99 1 Basic Data 2 Default values 4 Scheduling 6 Capacities Test: CR02: Work center TEST99 => No effect
 CR01: New work center of category PL99 => No effect (exit without saving) Assign screen control to work center category PL99 Test: CR02: Work center TEST99 => It works – there are only four tab pages
 CR01: New work center of category PL99 => It works (exit without saving)

Work Center Configuration: Field Control You can define a separate field control for each work center category. Several work center categories can use the same field selection.

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Figure 190: Configuring Work Centers: Field Selection Control

The field control is defined for each screen of the work center. For each screen, you see the fields for which you can set the display. You can define the setting for each field as general, meaning the same for all work center categories. You can also define this specifically for one work center category, meaning . for one type of field selection. You can produce a list of the settings for each field. You can define the following settings for a field: • • • • •

Hide completely Display only (here, for example, fix the field contents by forcing a value from the default work center) Ready for input Ready for input and required In addition, you can highlight the field

Configuring Work Centers – Field Selection Control Use the slide and the demonstration to explain the options for maintaining field control: • • •

Work center category-specific For several work center categories Cross work center category

The influencing field type of field control is not the work center category, but the work center category is assigned in maintenance there.

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Demonstration of Field Control As in the exercise: Adapt the field selection control for work center category PL## on tab pages Basic Data and Capacities according to your requirements as follows: •

•

Hide the fields Transition matrix, QDR system and Supply area on the basic data tab page, and define the field Person responsible as a highlighted, required field. Hide the Other formula and Internal distribution fields on the capacities tab page.

Following steps: 1.

Create work center (1000, XXX, PL99) Hint: => The description is the only required field (not modifiable)

2.

(2. mode) Customizing → Field control → Screen group - Basic data → Influencing value: PL99 Use the settings above Then in the „overview of influences", check => Basic data Two old, unspecified influences (storage location, mixed material ... hidden), 3 new entries with PL99 => Capacities

3.

No unspecified influences, 2 new entries with PL99 (1. mode) Exit work center maintenance (do not save) CR02: with TEST99 => No effect
 CR01: with new work center => No effect


4.

(2. mode) Customizing → Work center categoryfield selection: Assign PL99 to work center category PL99

5.

Repeat first mode => each will have influence

Control Key The control key is the central control element of the process.

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Figure 191: Control Key

The control key is a required field for the process. The control key can originate from the work center, either as a reference or as a proposal. You use the control key to define whether an operation (also suboperation, activity element, phase, or secondary resource): • • • • • •

Is read in scheduling Is read in capacity planning Is read in worklists in quality management (inspection characteristics) Is read in costing Automatically posts a goods receipt if a confirmation is entered for this operation Prints related shop floor papers (Print indicator), where this is defined for the order type, plant, and MRP controller, and where the control key is checked when printing shop floor papers:

•

– Prints time tickets ( Print indicator must be set first) – Prints confirmation slips ( Print indicator must be set first) Is processed externally

• •

– = internally processed – “+” = externally processed – “X” = internally processed / can be processed externally Can be considered in scheduling (indicator Sched. external op.) Supports confirmation: – – – –

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= possible, but not required 1 = milestone confirmation 2 = required 3 = impossible

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Standard Value Key

Figure 192: Standard Value Key

Step 1: Check the parameters defined. For standard value keys, only parameters with the original two standard values of operation can be used. Step 2: Define the standard value key. You use this to define how many of the maximum of six standard values are used. By assigning parameters to the individual elements of the standard value keys, you define the meaning of the individual standard values, including dimension, unit of measure, format, and description. Standard Value Key The standard value key offers the user up to six fields for entering standard values in operations. Show: (CA01) • •

An operation without a work center does not have any standard values An operation with a work center has default values according to the work center

Show in →Customizing(no need to create new entries): Define parameters (origin 2 only , for example, SAP_01 to SAP_06, not SAP_14 (user field) ) Store standard value key (parameter SAP_14 cannot be used here)

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Configuration of Scheduling Including Formulas

Figure 193: Execution Time

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

Figure 194: Formulas

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Formulas can be assigned to each capacity in the work center to calculate the capacity requirement. At the same time, formulas can also be permitted for different functions (capacity requirement, scheduling, and costing). Generation controls the immediate code generation for the formula. If no code is generated in formula maintenance, it is generated at execution time. There is a maximum of three lines per formula. Possible arithmetical operations are +, -, *, /, SIN, COS, DIV, MOD, SQRT, EXP, and LOG. Conversion of units of measure takes place automatically.

Figure 195: Setting Up Formulas

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Formula parameters are differentiated according to their origin. The following origins for a formula parameter can be defined in Customizing: •

• • • •

•

•

General operation value: The parameter is linked to a field in the general operation data. The value of this field is entered in the formula. Typical fields are lot size, base quantity, number of splits (partial lots), and number of employees. Work center constant: The parameter is assigned a constant value in the work center. This value is used in the formula. Standard value: Using the standard value key, you can assign a standard value that is used as a parameter in the formula. User field in the operation: The value of a custom field in the operation is assigned to the parameter. Value from PRT assignment: This could be either the quantity or the usage value of the production resource/tool (PRT). This parameter can only be used for formulas that are used for PRT management. PRT constant: You assign a constant value to this parameter in the PRT master record. These formula parameters can only be used in formulas for PRT management. General formula constant: A value is assigned to this parameter, which is then used in the application.

Configuration of Scheduling Execution Time Formulas Setting Up Formulas Formulas and Standard Values The control key controls for which activities an operation is permitted. Standard values must be maintained for planning of these activities, or first you need to use the standard value key in order to allow standard values to be maintained. For scheduling, capacity planning, or costing, you need formulas. This is discussed here by referring to scheduling, or execution time. Demonstration of Setting Up Formulas As in the exercise, show how to create parameters and formulas: Create a formula for periodical setup at a work center. In other words: First define a formula parameter for the additional set-up time and a formula parameter for the period, expressed as a quantity, after which the set-up is to be repeated. The parameter values should have their origin in a standard value in the operation = 2.

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Periodic setup

Sinterval

Parameter

SAP199

SAP299

Short keyword

Perd. Set-up

Sinterval

Keyword

Perd. Sint 99

Sinterval 99

Dimension

Time (TIME)

W/o dimensions

Standard value Standard value unit

1 Minutes (MIN)

Piece(PC)

Now define a formula SAP199 for periodic set-up at your work center, with the description Psetup . • • • •

Only allowed for scheduling Generated immediately Machine * Operation quantity / Base quantity + Periodic setup * ( (Operation quantity – 1 ) / Setup interval ) SAP_02 * SAP_09 / SAP_08 + SAP199 * ( ( SAP_09 - 1 ) / SAP299 )

Define a new standard value key S99 with the description Key PR99 with the following values: Setup time

SAP_01

Machine time

SAP_02

Perd. Sint 99

SAP199

Sinterval 99

SAP299

Test the formulas on the scheduling screen of a new work center: Create work center P-99 with work center category PL99 copying from 1905. Copy: Copy everything and display all screens. Save the work center. Replace the processing formula key for execution time with the formula key SAP1## that you created. Note the warning messages after you have confirmed the entry. Change the standard value key and test your formula on the Scheduling screen.

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Operation quantity

101 pieces

Setup time

10 minute

Machine time

1 minute

Psetup

5 minutes

Sinterval

50 pieces

=> Processing time 121 minutes

Capacity Categories and Capacities, Including Shift Sequences

Figure 196: Capacity Categories and Capacities

• •

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Creating capacities Assigning capacities to a work center, including intervals of available capacity, shift sequences, shifts, and so on

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Figure 197: Shift Sequences

The data in the environment for defining shift sequences can be grouped. This helps structuring and selection. 1.

2.

3.

Create the work break schedules. Work break schedules can contain several breaks. A break is a time interval at a fixed time or at a time relative to the start of the shift, which is defined later. Define the individual shifts. A shift is a fixed time interval. You can assign a work break schedule to a shift. From this time interval and the breaks within the assigned work break schedule, the working time is calculated. Define the shift sequences. A shift sequence can consist of several lines (shift numbers). For each line, you can assign a shift from step 2 to each weekday.

Capacity Categories and Capacities Explain the possibilities for storing available capacities at the work center. Refer also to the options of • • •

Default capacity Copy template of capacities and Pool capacities

Continue showcase from above. In other words: Transaction CR02 in work center PL99 (1000)

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→ Capacities 1. 2.

3.

Pushbutton „ Template or (shift + control +0). In other words: Copy available capacity from other work center. Pushbutton „Create capacity or (shift + F4)“
 Here, you can work with a reference capacity (which can also be copied) 
or a pooled capacity (both previously created using CR11). New available capacities work with default capacity, if available.

Here, also show the assignment of shift sequences. (“2S”, “3S”, “PP” ) → Customizing Show capacity categories and default capacity Shift sequences Briefly explain the structure for maintenance of shift sequences. If you have time, you can show this in Customizing, too.

Configuration of Scheduling Execution Time Formulas Setting Up Formulas Formulas and Standard Values The control key controls for which activities an operation is permitted. Standard values must be maintained for planning of these activities, or first you need to use the standard value key in order to allow standard values to be maintained. For scheduling, capacity planning, or costing, you need formulas. This is discussed here by referring to scheduling, or execution time. Demonstration of Setting Up Formulas As in the exercise, show how to create parameters and formulas: Create a formula for periodical setup at a work center. In other words: First define a formula parameter for the additional set-up time and a formula parameter for the period, expressed as a quantity, after which the set-up is to be repeated. The parameter values should have their origin in a standard value in the operation = 2.

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Periodic setup

Sinterval

Parameter

SAP199

SAP299

Short keyword

Perd. Set-up

Sinterval

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Keyword

Perd. Sint 99

Sinterval 99

Dimension

Time (TIME)

W/o dimensions

Standard value Standard value unit

1 Minutes (MIN)

Piece(PC)

Now define a formula SAP199 for periodic set-up at your work center, with the description Psetup . • • • •

Only allowed for scheduling Generated immediately Machine * Operation quantity / Base quantity + Periodic setup * ( (Operation quantity – 1 ) / Setup interval ) SAP_02 * SAP_09 / SAP_08 + SAP199 * ( ( SAP_09 - 1 ) / SAP299 )

Define a new standard value key S99 with the description Key PR99 with the following values: Setup time

SAP_01

Machine time

SAP_02

Perd. Sint 99

SAP199

Sinterval 99

SAP299

Test the formulas on the scheduling screen of a new work center: Create work center P-99 with work center category PL99 copying from 1905. Copy: Copy everything and display all screens. Save the work center. Replace the processing formula key for execution time with the formula key SAP1## that you created. Note the warning messages after you have confirmed the entry. Change the standard value key and test your formula on the Scheduling screen. Operation quantity

101 pieces

Setup time

10 minute

Machine time

1 minute

Psetup

5 minutes

Sinterval

50 pieces

=> Processing time 121 minutes

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Other Check Tables

Figure 198: Other Check Tables

These check tables are found in Customizing, and some of them can also be found also in the work center menu by choosing Environment → Current settings. Suitability and wage group are parameters from human resources. These are defined here if you do not use the SAP solution for human resources. Other Check Tables All of these check tables are, from a PP point of view, purely check tables with exclusive selection help. Link to HR: See notes for slide. Other Customizing points in the work center menu are: • • • • • • •

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Task list usage (see next chapter) Move time matrix (already covered in PLM111) Define subsystems (= maintain RFC connection and destination) Key for performance efficiency rate (not here, CO topic) Distribution (covered by course SCM360) Alternative activity texts (= overriding activity type descriptions -> CO topic) 
Points on available capacity (covered by course SCM940)

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Exercise 31: Work Center Category and Field Selection Control, Default Work Center (Optional) Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Set up a work center with a separate screen sequence • Set up a work center with a separate field sequence • Set up a work center category with a default work center

Business Example You are responsible for the system settings for work centers. A new work center category is to be set up for work centers in discrete manufacturing.

Task 1: Create a new work center category for your area of responsibility. 1.

Use work center category number PL## and the description Category ##.

2.

Set up the work center category for the task list application Routings for production.

Task 2: Define a special screen sequence for work center category PL##. 1.

For your work center category PL##, set the following screen selection sequence: basic data, defaults, capacities, scheduling, costing, and technology. Apart from the basic data, no other views need to be required.

Task 3: Adapt the field selection control for work center category PL## on tab pages Basic data and Capacities according to your requirements as follows: 1.

Hide the Transition matrix field on the basic data tab page, and define the field Person responsible as a required field.

2.

Hide the Other formula and Internal distribution fields on the capacities tab page.

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Task 4: Assign screen sequence and field selection to a work center category. 1.

Assign the screen sequence and field selection you have created to your work center category PL##.

Task 5: Create a default work center in plant 1000 for the work center category PL## you defined in the first task. 1.

2.

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Maintain the following data on the Basic data tab page: Task list usage

All task list types

Standard Value Key

Normal production

Maintain the following data on the Default values tab page: Control key

Choose one of the PP series control keys (PP01, PP02 through PP99). It must allow scheduling, capacity planning, and costing. It must also print time tickets and allow confirmations.

Units of measure for standard values

Minute

3.

Maintain capacity category machine on the Capacities tab page:

4.

Create a work center in plant 1000 to check the settings for the screen sequence and field selection.

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Solution 31: Work Center Category and Field Selection Control, Default Work Center (Optional) Task 1: Create a new work center category for your area of responsibility. 1.

Use work center category number PL## and the description Category ##. a)

In Customizing, choose Production → Basic data → Work center → General data → Define work center category. Choose New Entries. Cat.

PL##

Description

Category ##

Save. 2.

Set up the work center category for the task list application Routings for production. a)

Select your new line and choose Application in the dialog structure. Click New Entries for the selection of application P. Choose Save.

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Task 2: Define a special screen sequence for work center category PL##. 1.

For your work center category PL##, set the following screen selection sequence: basic data, defaults, capacities, scheduling, costing, and technology. Apart from the basic data, no other views need to be required. a)

In Customizing, choose Production → Basic data → Work center → Set up work center screen sequence. Make the following entries for work center category PL##: 2

Default values

3

Capacities

4

Scheduling

5

Costing

6

Technology

Delete the numbers of screens that are not required. Choose Save.

Task 3: Adapt the field selection control for work center category PL## on tab pages Basic data and Capacities according to your requirements as follows: 1.

Hide the Transition matrix field on the basic data tab page, and define the field Person responsible as a required field. a)

In Customizing, choose Production → Basic data → Work center → General data → Define field selection. Select the screen group Basic data and select influencing. Use your work center category PL## as the value for influencing, then make absolutely sure you choose Enter. Set the Transition matrix field to hide and the Person responsible field to required entry.

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2.

Hide the Other formula and Internal distribution fields on the capacities tab page. a)

Push-button Screen group Select the screen group Capacity and select influencing. Use your work center category PL## as the value for influencing, then make absolutely sure you choose Enter button. Set the Other formula and Internal distribution fields to Hide. Choose Save.

Task 4: Assign screen sequence and field selection to a work center category. 1.

Assign the screen sequence and field selection you have created to your work center category PL##. a)

In Customizing choose, Production → Basic data → Work center → General data → Define work center category. Assign field selection PL## and screen sequence PL## to your work center category PL##. Choose Save.

Task 5: Create a default work center in plant 1000 for the work center category PL## you defined in the first task. 1.

Maintain the following data on the Basic data tab page: Task list usage

All task list types

Standard Value Key

Normal production

a)

In Customizing, choose Production → Basic data → Work center → General data → Define default work center. Plant

1000

Work center category

PL##

Continue with Enter or push-button Basic Data (F5). Task list usage

009

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Standard Value Key

SAP1

Hint: In the field selection control for work center category PL##, you defined that the Person responsible field must always be maintained. The default work center is an exception, compared with ordinary work centers. 2.

Maintain the following data on the Default values tab page: Control key

Choose one of the PP series control keys (PP01, PP02 through PP99). It must allow scheduling, capacity planning, and costing. It must also print time tickets and allow confirmations.

Units of measure for standard values

Minute

a) 3.

Switch to the Default values tab page. Control key, for example PP01.

Maintain capacity category machine on the Capacities tab page: a)

Switch to the Capacities tab page. Capacity Category: 001 Choose Save.

4.

Create a work center in plant 1000 to check the settings for the screen sequence and field selection. a)

From the SAP Easy Access screen, choose Logistics → Production → Master data → Work centers → Work center → Create. Plant

1000

Work Center



Work center category

PL##

Choose Enter. Note: Info message: “Values were set from the default work center.” Person responsible is now mandatory. b)

Select the Capacities tab. Note: The Internal Distribution and Other Formula fields are hidden.

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Exercise 32: Optional: Work Center Formulas Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create and test formulas

Business Example As a member of the project team, you are responsible for feasible and exact scheduling of the company’s products You first need to set up formulas.

Task 1: Create a formula for periodically repeating setup at a work center. To be able to create and test the formula, it is necessary not just to define the formula parameters for the formula, but also to define a standard value key that supplies the formula with values. 1.

First define a formula parameter for the additional setup time and a formula parameter for the period, expressed as a quantity, after which the setup is to be repeated. The parameter values should have their origin in a standard value in the operation. Data for the group parameters: Periodic Setup

Sinterval

Parameter

SAP1##

SAP2##

Parameter Text

Perd. Set-up

Sinterval

Keyword

PS group ##

SI group ##

Dimension

Time (TIME)

Without dimensions (AAAADL)

Standard value Standard value unit

1 Minutes (MIN)

Piece(PC)

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2.

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Define a formula for periodic setup at your work center. Call the formula SAP1## with the description PS group ##. This formula must be valid only for scheduling and must be generated immediately when you save. Use the parameters from the table for this. The formula is Machine * Operation quantity / Base quantity + Periodic setup * ( (Operation quantity – 1 ) / Setup interval ).

3.

Define a new standard value key so that the parameters in the formula can be supplied with values. The standard value key should allow entries for setup time, machine time, and additional setup after 50 pieces. The key name is S## with the description SI group ##.

Task 2: Test the formulas on the scheduling screen of a new work center.

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1.

Create a new work center, PL##, with work center category PL##. Copy the Basic data, Default values, Capacities, and Scheduling screens from work center 1905. The description of the work center is Formula test ##. Save the work center.

2.

In the previous step, you saw a warning message, and you now want to respond to this. Make the relevant change in your work center.

3.

Now test your formula on the Scheduling screen. Enter the following values: Field

Entry

Operation quantity

101 pieces

Setup time

10 minutes

Machine time

1 minute

PS group ##

5 minutes

SI group ##

50 pieces

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Solution 32: Optional: Work Center Formulas Task 1: Create a formula for periodically repeating setup at a work center. To be able to create and test the formula, it is necessary not just to define the formula parameters for the formula, but also to define a standard value key that supplies the formula with values. 1.

First define a formula parameter for the additional setup time and a formula parameter for the period, expressed as a quantity, after which the setup is to be repeated. The parameter values should have their origin in a standard value in the operation. Data for the group parameters: Periodic Setup

Sinterval

Parameter

SAP1##

SAP2##

Parameter Text

Perd. Set-up

Sinterval

Keyword

PS group ##

SI group ##

Dimension

Time (TIME)

Without dimensions (AAAADL)

Standard value Standard value unit

2.

1 Minutes (MIN)

Piece(PC)

a)

In Customizing, choose Production → Basic data → Work center → General data → Standard value → Define parameters.

b)

Choose the New Entries button.

c)

Enter the parameters according to the table with origin key 2.

Define a formula for periodic setup at your work center. Call the formula SAP1## with the description PS group ##. This formula must be valid only for scheduling and must be generated immediately when you save. Use the parameters from the table for this.

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The formula is Machine * Operation quantity / Base quantity + Periodic setup * ( (Operation quantity – 1 ) / Setup interval ). a)

In Customizing, choose Production → Basic data → Work center → Capacity planning → Work center formulas → Set up work center formula definition.

b)

Choose the New Entries button.

c)

Enter the Formula key SAP1## and Description PS–Group ##. Hint: • • •

3.

You determine the necessary parameter ID by means of the search field for parameters. Upper/lowercase and line breaks do not affect the formula. Insert a blank before and after special characters (operators).

d)

Enter the formula SAP_02 * SAP_09 / SAP_08 + SAP1## * ( ( SAP_09 - 1 ) DIV SAP2## ).

e)

Set the Generate and Allowed for scheduling flags.

Define a new standard value key so that the parameters in the formula can be supplied with values. The standard value key should allow entries for setup time, machine time, and additional setup after 50 pieces. The key name is S## with the description SI group ##. a)

In Customizing, choose Production → Basic data → Work center → General data → Specify standard value key.

b)

Choose the New Entries button.

c)

Enter the Standard value key S## and the Description SI Group ##. Include the following parameters in the standard value key:

d)

Field

Entry

Setup time

SAP_01

Machine time

SAP_02

PS group ##

SAP1##

SI group ##

SAP2##

Choose Save.

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Task 2: Test the formulas on the scheduling screen of a new work center. 1.

Create a new work center, PL##, with work center category PL##. Copy the Basic data, Default values, Capacities, and Scheduling screens from work center 1905. The description of the work center is Formula test ##. Save the work center. a)

From the SAP Easy Access screen, choose Logistics → Production → Master data → Work centers → Work center → Create . Enter the data from the table below.

2.

Entry

Plant

1000

Work Center

P-##

Work center category

PL##

Reference plant

1000

Reference work center

1905

b)

Choose Enter.

c)

Ignore the warning message (different work center category) by choosing Enter again.

d)

In the Copy from... dialog box select Basic data, Defaults, Capacities, Scheduling and choose Copy.

e)

On the Basic Data view, enter the description: Formula test ##

f)

Go to the Scheduling tab page and replace the Processing formula with the one you created.

g)

A warning message will appear letting you know that parameters in your formula with origin Standard value in the operation do not appear in the Standard Value Key. Therefore, the system will not be able to determine the value of these parameters.

h)

Choose Enter to work through the warning but stay on this screen.

In the previous step, you saw a warning message, and you now want to respond to this. Make the relevant change in your work center. a)

3.

Field

Without leaving the work center, go to the Basic data tab page and overwrite the standard value key SAP1 with S##.

Now test your formula on the Scheduling screen. Enter the following values:

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Field

Entry

Operation quantity

101 pieces

Setup time

10 minutes

Machine time

1 minute

PS group ##

5 minutes

SI group ##

50 pieces

a)

Go to the Scheduling tab page and choose the Test formula button. Enter the values from the exercise and choose Calculate.

b)

The calculated overall execution time is 121 minutes, so setup was repeated twice.

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Lesson Summary You should now be able to: • Define default values for work centers • Explain the configuration settings regarding work centers • Create and test work center formulas

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Configuring the Routing Lesson Duration: 45 Minutes

Lesson Overview In this lesson you will learn about the customizing settings that controll the routing at the header level and also the item level.

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

Define system settings for routings

Business Example In the project team, you are responsible for routing administration. You need to be aware of what options your company can take advantage of to adapt their existing routings to SAP ERP.

Configuring Routings: Control Data In this step, you define number ranges for groups of routings, reference operation sets, rate routings, and reference rate routings. To create a these objects, SAP R/3 requires a unique group number. You can create any of these objects with or without a group. If you do not enter a group number, the system assigns one to the task list. The internal group number is within the number range you define in this step. You can also define number ranges for external assignment of group numbers.

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Figure 199: Routing Configuration: Control Data

In the next step, you assign number ranges you defined in the previous step to the respective task list types. Both internal and external number ranges are assigned here. Here you can also activate the following options for each task list type: • •

Write change documents Last maintained value for the material (and plant of the material), task list group, and sales document will default in task list maintenance Last maintained refers to the last entry of a specific user, and not the last entry in the system. If you would like to access fixed-user values instead of the last maintained value, do not activate this option. Also select SET parameters and GET parameters in the field attributes of the respective field, such as the Material field. Entering a fixed value in the user parameters alone is not sufficient.

•

Authorization check for deletion active. You use this indicator to specify that a user requires deletion authority for the relevant task list to delete a task list, change the deletion flag for a task list, delete a sequence of a task list, or delete an operation or phase of a task list. If you do not set this indicator, the user only needs change authority to carry out these activities for the relevant task list type.

•

Check material type against components

In this step, you maintain column headings for standard values on the operation overview. If all work centers where operations are processed use the same descriptions in the standard value key, the system dynamically determines a common description for the standard value column heading. If no common header can be determined for a column of standard values, the system sets the description from the Customizing table according to task list type. The same procedure applies when a sequence or a task list is created for the operation overview.

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In this step you specify the line lengths of the various texts in routing long texts. The length of the short text on the corresponding overview and detail screens is always limited to 40 characters. If the long text has more than 40 characters, the short text will display only the first 40 characters. This table setting affects the long texts of the following objects: header, sequence, operation, suboperation, and PRT assignment.

Configuring Routings: General Data Define material type assignment: In this activity, you can define for each material type which task list types can be used to create routings.

Figure 200: Routing Configuration: General Data

Define routing status: The status defines: • • •

Whether a reference operation set can be used in routings (Released indicator) Whether the routing is released for costing Whether a consistency check is run before saving (for details of the scope of the consistency check, see the online help)

Define task list usage: You can use task list usages to create different task lists for a material and plant, and use routing selection to control selection. The only parameter that can be assigned to the usage here is the dynamic modification criterion, which is relevant to quality management only.

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The task list usage is used for: • •

Automatic selection ID (as priority list regarding routing category, usage, and status) or User selection (ABAP routine)

Configure planner group: Check table - selection criterion Overview variants: Overview variants can be defined for object overviews, where-used lists, and scheduling. These are not relevant to the engineering workbench environment.

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Facilitated Discussion

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson Summary You should now be able to: • Define system settings for routings

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Unit Summary

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Unit Summary You should now be able to: • Describe the process of influencing the field characteristics of the material master • Describe Process of configuring the screen layout of the material master • Set up a customized material master in Customizing • Test the settings by creating a material master • Describe the configuration activities surrounding the BOM header • Describe the configuration activities surrounding the BOM items • Define default values for work centers • Explain the configuration settings regarding work centers • Create and test work center formulas • Define system settings for routings

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Test Your Knowledge

Test Your Knowledge 1.

A new material type can be created by simply clicking New Entries and entering the data. Determine whether this statement is true or false.

□ □ 2.

True False

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

□ □ □ □ □ 3.

A B C D E

User ID Material type Plant Industry Transaction

Which of the following are required to be configured before you can create a BOM? Choose the correct answer(s).

□ □ □ □ □ 4.

A B C D E

BOM usage BOM status Item Categories User-specific settings None of the above

You can control which material types can be used as the header material when creating a BOM. Determine whether this statement is true or false.

□ □ 5.

True False

A material with any material type can be used as a BOM component and this cannot be changed in the system. Determine whether this statement is true or false.

□ □

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Which of the following can be set in the user-specific settings? Choose the correct answer(s).

□ □ □ □

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A B C D

Item increment Default item category for materials Default BOM usage Default BOM category

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Test Your Knowledge

Answers 1.

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

2.

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

3.

Which of the following are required to be configured before you can create a BOM? Answer: E Since all of the above can use the default settings delivered with your SAP ECC system or are optional configuration activities, none of them is required.

4.

You can control which material types can be used as the header material when creating a BOM. Answer: True In Materials types for use in BOMs, you can indicate which material types can be used as the header material in a BOM.

5.

A material with any material type can be used as a BOM component and this cannot be changed in the system. Answer: False In material types for BOM items, you can control which material types can be entered as components on the BOM.

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Which of the following can be set in the user-specific settings? Answer: A, B The item increment and the default item category for materials as well as several other settings can be set in the user-specific settings. It is not possible to default the BOM usage and BOM category in the user-specific settings since these are picked by the transaction or the entry screen prior to BOM maintenance.

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Course Summary

Course Summary You should now be able to: • •

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Use the relevant master data elements for the modelling of planning and production processes Evaluate, describe, and implement the options provided by SAP-ERP-based planning

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Course Summary

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Index B

D

batch management, 108 batch master record, 108 bill of material, 28 BOM alternative determination, 580 archiving, 178 by-product, 330 co-product, 328 comparison, 198 default settings, 575 explosion report, 196 modification parameters, 574 recursiveness, 177 status, 578 where-used list, 197–198 BOM categories, 155 BOM status, 157 BOM usage, 156 BOM validity, 167

Distribution channel, 25 Division, 25

C change material archive, 133 delete, 131 extending, 123 mass maintenance, 128 material status, 126 material type, 125 characteristic, 105 class, 106 class type, 105 classification, 102 Client, 21 Company code, 22 component allocation, 282 Continuous flow, 437

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E engineering change management, 302

F field selection, 552 Float before/after production, 432

G Group BOMs, 169

I Individual Capacities, 436 industry sector, 73 see also influencing factors

item category configuration, 582 variable size, 581

L low-level code, 160

M material assignment, 280 Material master, 27 material number, configuring, 73 material status, 126, 137 material type, 71, 135 Move time, 434 MRP area, 53 MRP groups, 82 MRP profile, 82

O Overlapping, 437

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P plant definition, 39 Plant, 22 Processing time, 434 PRTs, 472 Purchasing group, 23 Purchasing organization, 23

Q Queue time, 434

R Reduction measures, 438 routing component allocation, 282 material assignment, 280 reporting, 305 suboperation, 291 user- defined fields, 293 variable-size items, 283 routings, 31

Sales organization, 24 Scheduling margin Key, 432 screen sequence, 558 Setup time, 434 Shipping Point, 25 Splitting, 436 storage location, 45 Storage location, 22 subitems, 172 suboperation, 291

T Tear down time, 434

U unit of measure, 75 groups, 77

W Wait time, 434 work center, 30

S Sales Area, 25

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

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