TSCM42_EN_Col92_FV_Inst_A4.pdf

TSCM42 TSCM42 Planning & Manufacturing II SAP SCM

Date Training Center Instructors Education Website

Instructor Handbook Course Version: 92 Course Duration: 10 Day(s) Material Number: 50095466 Owner: Hochadel Bernd (D021005)

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

Copyright Copyright © 2009 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors.

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

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

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

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About This Handbook

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

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

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

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

Unit 1: Introduction........................................................ 1 Overview of the Training for Solution Consultant SCM Planning & Manufacturing........................................................2 Production Types of the SAP ERP and SAP SCM Applications ..7

Unit 2: Order-Controlled Production with Process Orders..... 21 Order-Controlled Production with Process Orders ............... 22 Elements, Functions, and Processing of a Process Order ...... 40

Unit 3: Repetitive Manufacturing ..................................... 89 Characteristics of Repetitive Manufacturing....................... 90 Functions and Process Steps in Repetitive Manufacturing.....109

Unit 4: Kanban........................................................... 149 Features of the KANBAN Procedure ..............................150 The KANBAN Procedure............................................156

Unit 5: Capacity Requirements Planning (ERP) ................. 171 Capacity Planning Environment....................................173 Capacity Evaluation .................................................180 Capacity Leveling in Table Form ...................................198 Available Capacity ...................................................214 Capacity Leveling in Graphical Form..............................220

Appendix 1: Summary Appendix 2: References

.............................................. 241 ............................................ 247

Appendix 3: Detailed Functions of Capacity Requirements Planning ................................................................ 249

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Contents

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Course Overview Production is part of the applications SAP ERP (Enterprise Resource Planning) and SAP SCM (Supply Chain Management) in the SAP Business Suite. You can use this to manage all the production activities within your supply chain in one integrated system, from planning through execution to analysis. The focus of this course is execution. The following topics are dealt with in particular: •

Order-Controlled Production with Production Orders This section is performed with the original files of customer training course SCM310.

• • • •

Order-Controlled Production with Process Orders Repetitive manufacturing KANBAN Capacity Requirements Planning (ERP)

Information on SAP software components The information in this course is based on the following SAP software components and releases: • •

SAP ECC Enterprise Central Component 6.0, EhP4 SAP SCM Supply Chain Management 7.0

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

Application consultants responsible for the implementation of shop floor control as part of the applications of SAP Business Suite

Course Prerequisites Required Knowledge • • • •

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SAP125 SAP Navigation (E-Learning) TSCM40 Planning & Manufacturing I SM001 Introduction to the SAP Solution Manager Additional e-learning products (see graphic 1)

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Course Overview

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Recommended Knowledge • • • •

SAPSCM: SCM Overview PLM100 Lifecycle Data Management SCM100 Planning Overview (ERP) SCM200 Planning Overview (SCM)

Course Duration Details Unit 1: Introduction Overview of the Training for Solution Consultant SCM Planning & Manufacturing Production Types of the SAP ERP and SAP SCM Applications

20 Minutes 60 Minutes

Unit 2: Order-Controlled Production with Process Orders 70 Minutes Order-Controlled Production with Process Orders Exercise 1: Master Data of Order-Controlled 30 Minutes Production with Process Orders Elements, Functions, and Processing of a Process 145 Minutes Order Exercise 2: Integration with Planning; Process 30 Minutes Order Creation with Planned Orders Exercise 3: Process Order Release; Processing an 30 Minutes Order with a PI Sheet Unit 3: Repetitive Manufacturing Characteristics of Repetitive Manufacturing Exercise 4: Master Data - Optional Functions and Process Steps in Repetitive Manufacturing Exercise 5: Integration with Production Planning and MRP in the ECC System Exercise 6: Line Loading Planning in the ECC System Exercise 7: Material Staging and Backflush

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40 Minutes 20 Minutes 115 Minutes 20 Minutes 20 Minutes 20 Minutes

Unit 4: Kanban Features of the KANBAN Procedure The KANBAN Procedure

15 Minutes 20 Minutes

Unit 5: Capacity Requirements Planning (ERP) Capacity Planning Environment Capacity Evaluation Exercise 8: Standard Overview Capacity Leveling in Table Form Exercise 9: Tabular Capacity Planning Table Available Capacity

60 Minutes 45 Minutes 15 Minutes 120 Minutes 30 Minutes 120 Minutes

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Course Overview

Capacity Leveling in Graphical Form Exercise 10: Planning Strategies

45 Minutes 20 Minutes

Course Goals This course will prepare you to: •

Understand the positioning, integration, and functions of the production area within the SAP ERP (Enterprise Resource Planning) and SAP SCM (Supply Chain Management) solutions Get an overview of the supported production types and Capacity Requirements Planning (ERP)

•

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

Describe basic shop floor control procedures and functions and understand simple scenarios in the SAP System Use capacity planning functions for your consulting activities

•

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

SAP ERP Central Component 6.0 SAP SCM 7.0

LOCATION FOR THE INFORMATION XML-BASED TRAINING MATERIAL. INSTRUCTOR HANDBOOK In addition to the Instructor Handbook for XML-based training material, the most important recommended information is placed in a separate Instructor guide, TSCM42 Trainerguide, which you can find at http://service.sap.com/curr-info RECOMMENDED INFORMATION HINTS ON PREPARING THIS COURSE Remember to check for additional information not published after the course material was finally released. For latest information or course updates see additional Instructor Guide/System Setup Guide or Trouble Shooting Guide on SAP Service Marketplace under the alias http://service.sap.com/curr-info TRAINING SYSTEM

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Course Overview

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Your training systems will be available and accessible on Sunday evening (CET time zone) in the week the training takes place. Do not use the system or prepare your course before that time. The system may still be in use by another course or in the refresh procedures of the IT preparation for your course. If you need a test/prep. system before your course takes place, see details under the section “Test/Prep. System”. MATERIAL REQUIRED FOR PARTICIPANTS In this course the following training material is necessary: • •

For the first course week: SCM310 Coll. 92 For the second course week: TSCM42 Coll. 92

DATA REQUIRED For this TSCM42 course you need a training landscape consisting of an SAP ERP 6.0 system with enhancement package 4 and the corresponding SAP SCM 7.0 system. This means that CIF integration must exist and be active between both systems. Test/Preparation System There are test/prep systems for most SAP courses. You can find the necessary information at http://service.sap.com/curr-info. If you cannot access this site, ask the responsible education coordinator (the person who send you this guide) to provide you with the relevant information. If no test/preparation system exists for the course, but testing or preparation is essential, let the education department order or book a system via a CSS ticket at least one week before the training. Please note that test/preparation systems must not be used for training without the permission of KPS. An access violation fee will be charged. Using Training WTS farm Nearly all SAP courses are designed to be taught via SAP Training Window Terminal Server Farms (WTS farms) so that customers can be trained on-site (on-site training). Unless the course restrictions specify another WTS farm or the use of the local PC front end, always use the "Common Training" WTS farm for training. Only use SAP software on the local PC front end in SAP-owned training

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Course Overview

centers that have good network bandwidth connections. Using SAP software on the local PC front end restricts the training support to the local IT support. The global training support can only support training courses via Training WTS farms. •

Training at SAP training centers/internal SAP training The internal connectivity to the training WTS farms can only be used inside the SAP network infrastructure. To connect to the training WTS farm use http://wts.wdf.sap.corp:1080. Choose a region (AMERICAS, EMEA, or APJ). Select the "Training Zone" menu. Connect to "Common Training" if no other WTS farm is specified for the training course.

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Customer on-site training / third party training center Customer Onsite training can only connect to SAP training WTS farm via the SAP Citrix Secure Gateway (SAP CSG). You therefore need a CSG-User ID. The User ID needs to have been created by the education department in time for the training. The data (User ID and password) are delivered to you by the education department. The instructor and participants use the same dedicated CSG user ID and password for training. To connect to the training WTS farm, use http://mywts.sap.com. Choose a region (AMERICAS, EMEA, or APJ). Enter the CSG user ID and password, and log on. Select the ‘Training’ icon. Connect to "Common Training" if no other WTS farm is specified for the training course.

USER ID AND PASSWORDS FOR THE COURSE •

Training with Reference User IDs: To create the participants’ users (and, if necessary, your instructor user) directly before the course starts, log on to both training systems with the user “Training”. The monthly changed password should be delivered by your education department in the training information email/documentation. The standard format for User IDs is the Course ID (here: TSCM42), followed by the group number (here: ## being the group number 00 up to max. 30). The user ID will thus be “TSCM42-##”. The initial password is Fertigung. Use transaction ZUSR to copy these User IDs from the reference User ID (e.g. from your own user or from the user TSCM42MUSTER).

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ADDITIONAL PREPARATION IN THE SYSTEM •

Example ABAPs

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none CATTs/eCATTS

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There is a CATT for the course. This is executed centrally. Switching on/off table locking in SAP systems Do not switch off table locking in this course.

TECHNICAL HINTS Further activities to be carried out before the course commences: Take a look at the separate Instructor Guide TSCM42 Trainerguide

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Unit 1 Introduction

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Please use a separate, detailed Trainer Guide, which you can find on the SAP Corporate Portal.

Unit Overview Production Types of the SAP ERP and SAP SCM Applications In this unit, you will learn about the production types within the SAP Business Suite.

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

Obtain an overview of the scope of the training Name the production types supported in the SAP Business Suite.

Unit Contents Lesson: Overview of the Training for Solution Consultant SCM Planning & Manufacturing ......................................................................2 Lesson: Production Types of the SAP ERP and SAP SCM Applications ..7

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Unit 1: Introduction

Lesson: 2

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Overview of the Training for Solution Consultant SCM Planning & Manufacturing Lesson Duration: 20 Minutes

Lesson Overview Overview of the Training for Solution Consultant SCM Planning & Manufacturing

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

Obtain an overview of the scope of the training

Business Example None

Basic Training The training courses TSCM40 (Planning/Manufacturing I) and TSCM42 (Planning/Manufacturing II (including case study)) provide the participants with knowledge concerning 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 master data required for production (material masters, bills of material, work centers, routings, production resources/tools), including master data management, as well as about concepts and business processes of different planning areas. The training course deals with the processes of production planning using material requirements planning (PP-MRP module) based on a number of examples, as well as the different planning strategies for creating a product plan. The course also demonstrates evaluation methods for valuating the planning results. The training course TSCM42 (Planning/Manufacturing II (including case study)) familiarizes you with different options for controlling the production. This includes order-based production with production orders or process orders, repetitive manufacturing, Kanban and preproduction of production lots. These options provide effective support for the complete manufacturing process including the process steps material staging, sequencing, creation of shop floor

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Lesson: Overview of the Training for Solution Consultant SCM Planning & Manufacturing

papers, confirmations, backflushing, goods receipt, and settlement of production activities. The focus is on production order management. An overview is also provided of other options. The training course also contains a case study, which allows you to make practical use of the knowledge you acquired by configuring specified integrated business processes. At the end of the course, participants take an exam for certification as a Solution Consultant SCM - Planning/Manufacturing with SAP ERP 2005. The following diagram provides an overview of the scope of the training.

Figure 1: Basic Training: Consultant Profile SAP SCM - Planning & Manufacturing (for New Consultants)

Alternative Project Team Training The training material of the Consultant Academy is largely based on the relevant standard training, but is supplemented by topics that are relevant for consultants. The following table shows which topics were taken from the standard training and which topics are discussed additionally: Consultant Academy Training Course

Course Content

TSCM40 (Planning/Manufacturing I)

2 days PLM110 (Basic Data, Part 1) 3 days PLM111 (Basic Data, Part 2)

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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 SCM360 (Capacity Planning (ERP)) 1 day Repetitive Manufacturing and Process Manufacturing from SCM300 2.5 days Integrated Case Study 3 hours Certification Exam

Advanced Training Advanced training is geared towards consultants who have already participated in the detailed training for SCM - Planning/Manufacturing, or who have the equivalent skills and want to increase their knowledge of and specialize in the SCM(APO) module in the areas of Demand Planning (DP) and Supply Planning (SNP), and obtain certification. Advanced training involves participation in the customer training courses SCM220 (Demand Planning) and SCM230 (Supply Network Planning (SNP)). See also the current training program of SAP customer training.

Figure 2: Advanced Training: Consultant Profile SAP SCM - Planning

Additional Information •

•

4

The parts Basic Data, Part 1 and Part 2 (TSCM40) and Production Orders (TSCM42) are carried out with the original training materials of the relevant standard courses. The e-learning courses specified in figure 1 serve as the basis for the training.

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Lesson: Overview of the Training for Solution Consultant SCM Planning & Manufacturing

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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Unit 1: Introduction

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

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Lesson: 6

Lesson: Production Types of the SAP ERP and SAP SCM Applications

Production Types of the SAP ERP and SAP SCM Applications Lesson Duration: 60 Minutes

Lesson Overview In this lesson, you learn about the production types that are supported within the SAP Business Suite.

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

Name the production types supported in the SAP Business Suite.

For demonstrations and instructor notes, see the instructor guide on the SAP Corporate Portal.

Business Example A company implements the SAP Business Suite. As a consultant, you are either a member of the project team responsible for implementing the shop floor control functions or you are in the production department. You use various scenarios to gain an overview of the options and functions of the supported production types and capacity requirements planning (ERP).

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Overview of SAP Applications

Figure 3: SAP ERP Application Overview

SAP offers an SAP Business Suite, consisting of several applications, as part of its long-term product strategy. The Enterprise Resource Planning (ERP) application is a comprehensive application that allows a company to efficiently plan, manage, and check complex delivery, procurement, and production networks. This application supports synchronized and close interaction between all the departments (and people) involved in a supply chain. Customers, sales, production planning, manufacturing, warehouse management, purchasing, and vendors are all included in this complete solution. The SAP ERP application covers several areas (see above). For more information about the individual components of the SAP ERP application, see http://www.sap.com/solutions/businessmaps/solutionmaps/ and cross-industry business maps.

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Figure 4: SAP SCM Application Overview

SAP Supply Chain Management (SCM) is a comprehensive application that allows a company to plan, realize, and monitor complex delivery, procurement, and product relationships (supply chains) efficiently. This application supports a synchronized and close interaction between all departments (and people) involved in a logistics chain. Customers, sales, production planning, manufacturing, warehouse management, purchasing, and vendors are all included in this complete solution. The processing of cross-company or collaborative planning and procurement processes, which also allow a connection to open marketplaces, is a special feature of this solution. The SAP SCM application covers several areas (see above). For more information about the individual components of the SAP SCM application, see http://www.sap.com/solutions/businessmaps/solutionmaps/ and cross-industry business maps.

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Figure 5: SAP Components

For the most part, in-house production is realized with the SAP ECC system component: Advanced Planning and Optimization (APO) in SAP SCM provides considerably enhanced planning tools: With Supply Network Collaboration (SNC) it offers a tool for cross-system collaboration between companies, with Extended Warehouse Management (EWM) an enhanced warehouse management system, and with Event Management (EM) a tool to tracking events. SNC, EWM, and EM are also suitable for use as standalone systems. SAP BW (Business Information Warehouse) is used to store data separately across the company group for variable evaluations. SAP CRM offers more comprehensive sales order management options that those provided in SAP ECC. Interfaces that integrate ECC with SCM, BW, or CRM are provided with an appropriate plug-in (integrated in SAP ECC). The interface between ECC and SCM (APO) is called the Core Interface (CIF). Several interfaces (PP-PDC, PI-PCS, SAP ODA) and SAP Manufacturing Integration and Intelligence (SAP MII) software are available to integrate production with process-based command and control systems. The cross-system use of multiple system components and their applications can be simplified by giving end users role-based UIs (user interfaces). For the role of production scheduler you can use the SAP Enterprise Portal or the SAP NetWeaver Business Client.

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Figure 6: Process Integration and Intelligent Architecture

With SAP MII, SAP provides an adaptive manufacturing application for production. This composite application SAP® xApp Manufacturing Integration and Intelligence (SAP MII) gives manufacturing companies greater flexibility by improving the link between the SAP ERP application and the production process level, as well as providing employees with realtime information. You can implement SAP MII in a plant very quickly, thus extending the functions of the SAP NetWeaver® technology platform to production too. You can improve how you organize production, external procurement, and warehouse stock from a business perspective and adjust them dynamically in response to unexpected changes. Manufacturing companies are thus able to respond to realtime information from production immediately, enabling them to work faster and at lower cost. The application makes it easier for you to arrange the production processes as well as the corresponding areas (plant maintenance, quality management) more effectively. SAP MII provides standardized, preconfigured connectors to enable realtime data integration in Manufacturing Execution Systems (MES) and SCADA Systems (Supervisory Control and Data Acquisition). You can run realtime analyses and display the results in browser and role-based dashboards. They provide important information for checking and supporting decision-making, such as warnings, job lists, analyses, reports, and realtime messages about production variance. You can incorporate this information in role-based enterprise portals.

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Preconfigured dashboards are currently available for the roles of plant manager, production scheduler, quality officer, and maintenance manager. You can find information about MII in the Internet under http://www.sdn.sap.com/irj/sdn/bpx-manufacturing

Figure 7: Production Scheduler in the Enterprise Portal

This slide shows an example of the Overview page for a production scheduler’s portal. For the role of production scheduler, the Enterprise Portal allows you to actively process and track production orders, process orders, and other objects. The figure above shows an example of the Overview page for a production scheduler’s portal. You can see the worklist that the production scheduler has to process or check at the bottom left (production orders, quality notifications, inspection lots, malfunction reports, and maintenance orders). The following functions are possible: Change, display, and confirm orders. You can incorporate and execute any transactions and reports you wish. You can integrate any pages and iViews into the portal with ease. In order to use the portal, all you have to do is install an additional portal server. The software is included in SAP NetWeaver. If you want to learn about Enterprise Portal technology, you can attend the SAP training courses SAPEP and EP200.

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You can find information about the Enterprise Portal and roles in the Internet under http://www.sdn.sap.com/irj/sdn/bpx-manufacturing

Production Types Depending on the manufacturing process, product complexity, stability of production, and other criteria, a company has various requirements with regard to shop floor control. For this reason, SAP ERP und SAP SCM support a variety of production types.

Figure 8: Production Types (1)

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Figure 9: Production Types (2)

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Lesson: Production Types of the SAP ERP and SAP SCM Applications

Facilitated Discussion As part of the round of introductions, you can ask the participants about the requirements of their company or project.

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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Unit 1: Introduction

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Lesson Summary You should now be able to: • Name the production types supported in the SAP Business Suite.

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Unit Summary

Unit Summary You should now be able to: • Obtain an overview of the scope of the training • Name the production types supported in the SAP Business Suite.

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Unit Summary

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Test Your Knowledge

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Test Your Knowledge 1.

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Name the production types that are supported within the SAP Business Suite.

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Test Your Knowledge

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Answers 1.

Name the production types that are supported within the SAP Business Suite. Answer: • • •

Order-related production with production order Order-related production with process order Repetitive manufacturing:

•

– Period- and quantity-oriented production – Not order-related Kanban: –

•

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Replenishment-controlled using stock transfer, external procurement, in-house production via self-controlled control cycle Project-oriented production with production lot

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Unit 2 Order-Controlled Production with Process Orders

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To find out how the exercises fit into the course from a timing point of view, see the proposal in the instructor guide.

Unit Overview In this unit, you will learn about process order-controlled production.

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

Explain the characteristics of order-controlled production with process orders Describe the individual steps in process order management Describe the concept of process management and use a PI sheet to execute a process order Explain the special functions for process order management in the pharmaceutical area

Unit Contents Lesson: Order-Controlled Production with Process Orders ................ 22 Exercise 1: Master Data of Order-Controlled Production with Process Orders ......................................................................... 33 Lesson: Elements, Functions, and Processing of a Process Order....... 40 Exercise 2: Integration with Planning; Process Order Creation with Planned Orders .............................................................. 59 Exercise 3: Process Order Release; Processing an Order with a PI Sheet .......................................................................... 71

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Unit 2: Order-Controlled Production with Process Orders

Lesson: 18

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Order-Controlled Production with Process Orders Lesson Duration: 70 Minutes

Lesson Overview The following topics are dealt with in this lesson: • • • •

Application areas of process orders Process-order-controlled production: Characteristics Cross-application process flow Master data for process orders

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

Explain the characteristics of order-controlled production with process orders

For demonstrations and instructor notes, see the instructor guide on the SAP Corporate Portal.

Business Example Your company is a process manufacturing company. You produce order-related products. You are on the project team for implementing shop floor control functions based on process orders.

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Lesson: Order-Controlled Production with Process Orders

Application Areas of Process Orders

Figure 10: Application Areas of Process Orders

Process orders are used in different areas of the process manufacturing industry. Process orders can be used for various production procedures and identified, for example, according to the criteria product complexity and product stability.

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Process-Order-Controlled Production: Characteristics (1)

Figure 11: Process-Order-Controlled Production: Characteristics (1)

(*) Note: In process manufacturing, there are usually increased requirements with regard to the integration of batch management and quality management within the supply chain.

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Lesson: Order-Controlled Production with Process Orders

Figure 12: Process-Order-Controlled Production: Characteristics (2)

Notes: The central idea behind process orders corresponds in many ways to the idea behind production orders. The following basic functions are also supported by production orders but are normally used in process manufacturing: (1) You have to select a production version when you open an order (2) The materials in process manufacturing are normally managed in batches. There are functions for batch number assignment for the product and for batch determination of material components. (3) After an order is released, control recipes with parameters for the process control level can be generated by the system and sent to an external system or formatted within ECC in as a process instruction (PI) sheet to be processed interactively on the screen. Hint: For production orders, the synonyms control instructions (= control recipe) and operational method sheet (= PI sheet) are used.

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Unit 2: Order-Controlled Production with Process Orders

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Figure 13: Process-Order-Controlled Production: Characteristics (3)

Process management Process management is the interface between the process orders and the systems involved in process control. Due to its flexible structure, it can be linked to fully automated, partially automated, and manually operated lines. Process management includes communication with the process control level via the PI-PCS interface or PI sheets. Control recipes from released process orders are sent to process control systems or formatted as HTML PI sheets in the respective native language in the SAP ECC system. Process messages with actual process data are received from the PI sheet or the process control system in return. Hint: The process control functions are available as of Release ECC 6.0 Enhancement Pack 3 for production orders too. The following synonyms exist: Process integration (= process control), control instruction (= control recipe), operational method sheet (= PI sheet). SAP OPC data access (SAP ODA) SAP OPC data access (SAP ODA) enables the system to read and write data points and events using the OPC server for the ECC system. This function is also available with production orders.

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Lesson: Order-Controlled Production with Process Orders

OPC stands for “OLE for Process Control and Openess, Productivity and Connectivity”. OPC is a standard that uses COM/DCOM technology to define interfaces independent of the manufacturer for use in industry. The OPC standard was designed especially for the process control level. OPC servers allow access to various data sources (such as process control systems, programmable logic controllers, and temperature sensors) and thus provide process data that can be requested by OPC clients. SAP ECC with the SAP ODA component is an OPC server and client that can communicate with OPC servers. It makes data exchange between applications considerably easier. OPC clients and OPC servers are currently pc-based systems on which a Microsoft operating system runs. You can find further information on the OPC Foundation Web sites http://www.opcfoundation.org and www.opceurope.org. SAP MII With SAP MII Manufacturing Integration and Intelligence, SAP offers an adaptive manufacturing solution for production. SAP MII gives manufacturing companies increased flexibility through improved linking of the SAP ERP solution to the production process level and by making realtime information available to employees. You can use SAP MII both in the process order and production order environment. SAP MII provides standardized, preconfigured connectors to enable realtime data integration in Manufacturing Execution Systems (MES) and SCADA Systems (Supervisory Control and Data Acquisition). You can run realtime analyses and display the results in browser and role-based dashboards. They provide important information for checking and supporting decision-making, such as warnings, job lists, analyses, reports, and realtime messages about production variance.

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Cross-Application Process Flow

Figure 14: Cross-Application Process Flow

Process order management is a central part of a complex process chain starting with a requirement (planned or customer requirement) and ending with the goods issue of finished products. Process order management controls the whole process of in-house production of products. Process order execution is integrated with the functions of capacity requirements planning, costing, and inventory management. Integration is also provided with batch management and quality management, interfaces to process control systems, and laboratory information systems.

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Master Data for Process Orders

Figure 15: Master Data for Process Orders

Master data is data in the SAP system that remains unchanged over a long period of time. It contains information that is required in the same manner over and over again. The material is the central master record in Logistics. In general, SAP defines a material as a substance or commodity that is bought or sold on a commercial basis, or is used, consumed, or created in production. A batch is a uniquely identifiable partial quantity of a material. The batches of a material are managed in separate stocks. With regard to the production process, a batch is a quantity of a specific material produced during a standardized production run. This quantity, therefore, represents a non-reproducible unit with unique specifications. The master data for resources describes the means of production in the production process. A production version determines which alternative BOM is used in combination with which master recipe for process order manufacturing. The master data of the master recipes describes the non-order-specific production of one or more materials in a production run. Material BOMs show the structure of products that are produced in a company. They are usually created and maintained from the master recipe (integrated maintenance).

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Material and Batch

Figure 16: Material and Batch

In different sectors, especially in the process industry, it is necessary to work continuously through the logistic quantity and value chain using homogeneous partial quantities of a material. In the SAP system, batch master records always depend on material master records. Batches are created for a material. In general, the data of a material master is valid for all batches assigned to it. By contrast, a batch master record contains data that uniquely identifies the corresponding batch and characterizes the unit as one that cannot be reproduced. The characteristic batch specifications are assigned using characteristics from the classification system in the material master and are inherited by the corresponding batch master records. If you want a material to be produced and managed in batches, you have to set the subject to batch management requirement indicator in the material master record. A batch master record is usually created by the system in the background for certain business operations (such as goods receipt). Users can also create batch master records directly in master data maintenance.

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Batch Management in Supply Chain Management

Figure 17: Batch Management in Supply Chain Management

Batch management is used in all areas of Logistics. A batch can be traced across the whole supply chain, from the receipt of the raw material to processing in production and the creation of the final product, all the way to sales and delivery to the customer. You can use a batch master record to assign a batch to a material at different places along the supply chain. For example, if the partial quantity of a material subject to batch management requirement with certain specifications leaves a production process (process order), it is posted to stock with a batch number and can be uniquely identified there. If a batch with certain specifications is required in the supply chain, you can use the batch determination function to enable the system to locate suitable batches in stock. In production, for example, batch determination is used in a process order to find and withdraw suitable material components for the product to be produced.

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Unit 2: Order-Controlled Production with Process Orders

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Demo Scenario: Ice Cream Production in Plant 1100

Figure 18: Demo Scenario: Ice Cream Production in Plant 1100

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Lesson: Order-Controlled Production with Process Orders

Exercise 1: Master Data of Order-Controlled Production with Process Orders Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Name the master data that is important for process-order-controlled production • Select production versions in mass maintenance • Navigate from mass maintenance for production versions to master recipes • Navigate from a master recipe to the relevant BOM (integrated BOM maintenance)

Business Example Hint: This exercise is optional. You are an employee in a company that produces food products and alcoholic beverages. You are a member of the SAP project team and responsible for implementing the functions of order-controlled production with process orders. You will first get a general overview of the basic master data. Next you will display the master data production version, master recipe, and BOM for the product T-FI1## “Vanilla ice cream - packaged” and become familiar with the structure, basic data and navigation in these master records.

Task 1: 1.

First, gain an overview of the menu structure of the production planning and control functions for process industries. Which menu path takes you to these functions?

2.

Name the basic master data for process-order-controlled production

3.

Which menu paths take you to the maintenance transactions for material master records, batches, production versions, resources, and master recipes?

Continued on next page

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Task 2: Go to mass maintenance for production versions and select the production version(s) for the material T-FI1## Vanilla ice cream - packaged in plant 1100. 1.

Display the details for production version 0001. Which task list and which BOM are assigned to each other through the production version? ______________________________________________________ ______________________________________________________ For which lot size range and which time period is the production version valid? ______________________________________________________ ______________________________________________________

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2.

Navigate from mass maintenance to the master recipe for production version 0001.

3.

Get an overview of the master recipe structure and the data in the Recipe Header, Operations, and Materials views.

4.

From the Materials master recipe view, navigate to the BOM for material T-FI1##.

5.

Get an overview of the data in the BOM and then go back to the master recipe.

6.

Exit the master recipe and mass maintenance for production versions.

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Solution 1: Master Data of Order-Controlled Production with Process Orders Task 1: 1.

First, gain an overview of the menu structure of the production planning and control functions for process industries. Which menu path takes you to these functions? a)

SAP Menu Logistics → Production - Process → (...) The menus appear for - Master Data - Production Planning

(SOP, Production Planning, MRP)

- Shop Floor Control

(Process Order, Production Campaign, Process Planning, Process Management)

- Product Cost Planning 2.

Name the basic master data for process-order-controlled production a)

For more information, refer to the page “Master Data for the Process Order” in your training material. The basic master data is as follows: • • • • •

Material and Batch Resource Production Version Master Recipe BOM

Continued on next page

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Unit 2: Order-Controlled Production with Process Orders

3.

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Which menu paths take you to the maintenance transactions for material master records, batches, production versions, resources, and master recipes? a)

SAP Menu → Logistics → Production - Process → Master Data → Material Master → (…) → Material Master → Batch → (…) → Production Versions → Resources → (…) → Master Recipes → (…)

Task 2: Go to mass maintenance for production versions and select the production version(s) for the material T-FI1## Vanilla ice cream - packaged in plant 1100. 1.

Display the details for production version 0001. Which task list and which BOM are assigned to each other through the production version? ______________________________________________________ ______________________________________________________ For which lot size range and which time period is the production version valid? ______________________________________________________

Continued on next page

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Lesson: Order-Controlled Production with Process Orders

______________________________________________________ a)

SAP Menu → Logistics → Production - Process → Master Data → Production Versions Plant:

1100

Material:

T-FI1##

Enter Double-click the row for production version 0001 Lot size from 2000 to 10000 kg Plan Task List Type: Master Recipe Group: T-ICE## Group Counter: 1 BOM Alternative BOM: 1 Plan Task List Type:

Master Recipe

Group:

T-ICE##

Group Counter:

1

BOM Alternative BOM: 2.

Navigate from mass maintenance to the master recipe for production version 0001. a)

3.

Choose → Recipe

Get an overview of the master recipe structure and the data in the Recipe Header, Operations, and Materials views. a)

4.

1

Choose the appropriate tabs to navigate between the views.

From the Materials master recipe view, navigate to the BOM for material T-FI1##. a)

In the Materials view BOM push button

5.

Get an overview of the data in the BOM and then go back to the master recipe. a)

To exit the BOM, choose Back (F3).

Continued on next page

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Unit 2: Order-Controlled Production with Process Orders

6.

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Exit the master recipe and mass maintenance for production versions. a)

To exit the recipe, choose: Exit (Shift+F3) To exit mass maintenance for production versions, choose Exit (Shift +F3).

Facilitated Discussion Understand application areas and characteristics of shop floor control with process orders

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: Order-Controlled Production with Process Orders

Lesson Summary You should now be able to: • Explain the characteristics of order-controlled production with process orders

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Elements, Functions, and Processing of a Process Order Lesson Duration: 145 Minutes

Lesson Overview In this lesson, you learn about important elements and functions of a process order as well as the typical way it is processed.

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

Describe the individual steps in process order management Describe the concept of process management and use a PI sheet to execute a process order Explain the special functions for process order management in the pharmaceutical area

For demonstrations and instructor notes, see the instructor guide on the SAP Corporate Portal.

Business Example Important steps in process order management are order creation, batch determination, scheduling, availability checks, release, transfer of control recipes to process control, material withdrawal, confirmations, material delivery, and settlement. To link the process control level with process control systems and PI sheets, you must set up the process management functions. To manufacture pharmaceutical products, you must implement the following functions: Order approval, material identification and reconciliation, in-process quality checks, batch records, digital signature.

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Lesson: Elements, Functions, and Processing of a Process Order

Process Order

Figure 19: Processing a Process Order

The procedure involved in process order management can be divided into the following steps: • • •

Process Planning Process Order Execution/Process Management Order Closure

Many of these activities can run automatically or in the background, so that manual order management is minimized. WIP determination, variance calculation, and settlement are generally periodic work for Cost Object Controlling and are usually processed in the background. A number of settings available in Customizing allow you to successfully perform each step in order processing.

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Figure 20: Elements of the Process Order

Operations describe the different steps required during the production process. For a more detailed description of these steps, operations are assigned phases. Exactly one resource is assigned to an operation. At the same time, the resource assignment applies for all phases assigned to the operation. The processing sequence of the phases is defined in relationships. The material list is made up of components representing the materials entering and leaving the production process as well as temporarily existing materials and their planned quantities. It also defines the assignment of these material components to phases of the order according to their appearance in the process. In material quantity calculation, you define formulas to calculate the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the ingredients, yield ratios of the products and remaining materials as well as specific material attributes (for example, active ingredients). Phases are used for scheduling, determining capacity requirements, and costing. The dates and capacity requirements for operations are derived from the corresponding phases. Operations and phases can be assigned further resources or secondary resources, if required. The same business transactions can be executed for secondary resources as for phases. Secondary resources can, for example, be included in scheduling, capacity requirements planning, and costing.

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A control key must be entered for both the phases and the secondary resources. The control key is used to determine how an operation or phase is to be treated in operative applications such as process orders, costing, or capacity requirements planning. A standard value is a planned value used to execute a phase or a secondary resource such as the execution time. Standard values are used for calculations in costing, scheduling, and capacity requirements planning. Confirmations are entered for phases and secondary resources (however, not for operations). Data for Process Management: Option 1: Process instructions are structures used to transfer data from process orders to process control (PI sheets or process control systems). Process instructions are assigned to the phases of a process order. The process instructions are combined into control recipes, which are then transferred to the control recipe destinations defined for the phases. Data for Process Management: Option 2: The data for process management can be maintained alternatively in the form of XSteps (execution steps) as of SAP R/3 ERP and SCM Extension 2.00 (EA_APPL_2.00). Using XSteps allows you to maintain process instructions in the form of reusable modules that can be referenced. A standard XStep repository is available with version management.

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Order Creation Options

Figure 21: Order Creation Options

To create a process order and a planned order, a suitable production version is determined for the material based on the validity period and charge quantity range. A production version determines which alternative BOM in combination with which master recipe is used for production. If a process order is created without a planned order, it takes the recipe and BOM from the production version. When a planned order is converted, the production version created for it is made known to the process order and its recipe is transferred. The BOM is not reread, but rather the dependent requirements of the planned order are converted to reservations for the process order.

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Lesson: Elements, Functions, and Processing of a Process Order

Integration with Planning (ECC or SCM (APO))

Figure 22: Integration with Planning (ECC or SCM (APO))

For explanations about planning integration see the unit “Order-Controlled Production with Production Orders”. Process orders and production orders behave similarly in this regard.

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Order Creation with Planned Orders

Figure 23: Order Creation with Planned Orders

For explanations about order creation with planned orders see the unit “Order-Controlled Production with Production Orders”. Process orders and production orders behave similarly in this regard.

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Lesson: Elements, Functions, and Processing of a Process Order

Order Release Functions

Figure 24: Order Release Functions

Process orders have a status management that controls the possible processing sequence of the individual business operations. When an order is released, a status is set accordingly. The process order must have the status Released so that the business transactions for process order execution and process management can be executed. You can release individual phases and operations, one complete order, or several orders at once. Various activities can be triggered automatically when an order is released: • • • • •

Batch number assignment for the product Batch determination for the material components Material availability check Control recipe generation Generation of an inspection lot for an in-process quality check

The aims and methods of resource scheduling for process orders are the same as those for work center scheduling for production orders. They can be found in the unit Order-Controlled Production with Production Orders on the pages Detailed scheduling (work center scheduling) and example: Capacity planning table (APO).

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The availability checks for process orders are more or less the same as those for production orders. They are described in the unit Order-Controlled Production with Production Orders on the page Availability Check for Material, Capacity, PRT. Note here that production resources/tools are not supported in the process order. The functions for assigning batch numbers (for the product) and for batch determination (for material components) can be used for both process orders and production orders. A greater requirement for integration with batch management is usually found in process manufacturing.

Batch Determination

Figure 25: Batch Determination

You can use the batch determination function to assign batches with certain material specifications required for production. The system looks for batches in stock and selects them according to specific selection criteria. Based on the selection criteria and a search strategy, the system looks for and selects suitable batches in stock. An availability check is performed at batch level.

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Lesson: Elements, Functions, and Processing of a Process Order

The batch determination function is also available for the following applications: • • • • •

Production order Repetitive manufacturing Sales (sales order and delivery) Inventory management (goods movements) Warehouse management

Process Management

Figure 26: Process Management

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Process management is the interface between PP-PI and the systems involved in process control. Due to its flexible structure, it can be linked to fully automated, partially automated, and manually operated lines. Process management includes the following functions: •

Communication with the process control level via the PI-PCS interface or PI sheets: –

•

Receiving control recipes with process instructions from released process orders. The process instructions define in detail the process steps to be executed and the process data to be confirmed (using process messages). – Manual processing: Displaying control recipes in natural language in the form of PI sheets so that they can be displayed and maintained on the screen by the process operator – Automatic processing: Sending control recipes to process control systems. The data is transferred via the PI-PCS interface. – Receiving, checking, and sending process messages with actual process data from the process control system or the PI sheet. The data is transferred from the external system via the PI-PCS interface. Reading and writing data points and events using the function SAP OPC data access (SAP ODA) with the OPC server of the ECC system: – –

Reading and writing using a PI sheet Reading using the function for automatically creating process messages Hint: The functions described are available as of Release ECC 6.0 Enhancement Pack 3 for production orders also. For production orders, the synonyms of process integration (= process management), control instructions (= control recipe) and operational method sheet (= PI sheet) are used.

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Lesson: Elements, Functions, and Processing of a Process Order

HTML-Based PI Sheet

Figure 27: HTML-Based PI Sheet (I)

Figure 28: HTML-Based PI Sheet II

The SAP PI sheet favors processing on the screen, which means the process operator is to enter, confirm, or complete data interactively.

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In connection with the process instructions contained in a control recipe, the PI sheet has the following elements and functions: • • • • • • • •

Display of information about the process (control instructions, notes, and so on) Input fields and tables for entering process data, input validation, signatures Batch determination and batch check Process data calculation Reading and writing data from internal or external applications Link to QM results recording Sequence definition for determining the processing sequence of phases Comments on documentation and messages from process events

PI sheets are created in the HTML layout. The browser-based PI sheet gives you the advantage of a flexible, user-specific layout definition and allows you to define frames, for example, for linking to documents, graphics, the Internet, and Intranet.

Material Staging Procedures

Figure 29: Material Staging Procedures

The basis for material withdrawal for process orders are material withdrawal slips, pull lists, pick lists, and similar documents, as well as PI sheets and weighing systems linked via the PI-PCS interface.

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Lesson: Elements, Functions, and Processing of a Process Order

For explanations about material staging see the unit “Order-Controlled Production with Production Orders”. Process orders and production orders behave similarly in this regard.

Standard Postings for Process Orders

Figure 30: Standard Postings for Process Orders

The standard postings for process orders (goods issue, confirmation, goods receipt) can be entered manually in the ECC system, or using process messages from a PI sheet or a process control system. The functions and procedures for manual entry of process orders are more or less the same as those for production orders. They are explained in the unit Order-Controlled Production with Production Orders (goods issue posting; order confirmation; confirmation procedures; goods receipt posting). The process instructions of the order define which process messages are required by a PI sheet or a process control system.

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Confirmations are entered for phases and secondary resources (and not for operations). The simplest confirmation procedure is the confirmation for the process order. Hint: Backflushing using process messages from operational method sheets (= PI sheets) and process control systems is also available as of Release ECC 6.0 Enhancement Pack 3 for production orders. You can also execute backflushing in the SAP MII system.

Flexible Data Entry with Process Messages

Figure 31: Flexible Data Entry with Process Messages

Process messages are data structures with which actual data for a process is confirmed from process control to one or more destinations. You can define your own process messages in Customizing according to your own specific requirements. The SAP standard system contains a number of predefined message categories that enable you to transfer current data from process control to the ECC system.

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Lesson: Elements, Functions, and Processing of a Process Order

Production in Compliance with GMP

Figure 32: Functions for GMP-Compliant Production

The functions for GMP-compliant production (GMP = Good Manufacturing Practice) fulfill special requirements from the pharaceuticals industry (safe production, product liability, obligation to produce supporting documents). The functions flagged with (*) are supported exclusively as part of process orders. The other functions, which are not flagged, can also be used as part of production orders.

Figure 33: Production in Compliance with GMP

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The guidelines on Good Manufacturing Practices (GMP) laid down by the U.S. Food and Drug Administration (FDA) and other international institutions have become an international standard in many areas of process industries. In particular, they must be taken into account in processes of the pharmaceutical industry. You can specify that a process order can only be created if an approved recipe exists. This means the order data is locked and cannot be changed. The approval procedure is performed in SAP ECC Engineering Change Management. You use the material identification function to check whether the material that was picked for the process order is completely available at the production line and will be used in the correct sequence. You can exchange information about the product quality and analysis values between the production plant and the laboratory or the quality assurance system. To do this, you use the ECC Quality Management system. The inspection results can be automatically transferred to the class characteristics of the batch produced. You use the material reconciliation function to analyze and verify the ingredients and yield at the end of the production process. With regard to product liability, the batch record contains all planned and actual data for the production process of a batch. You can activate the digital signature function to execute certain business operations in the ECC system.

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Enhanced Functions for the Process Order

Figure 34: Enhanced Functions for the Process Order

The functions flagged with (*) are available for process orders only. The other functions listed are also supported in the production order.

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Process Manufacturing: Information Systems

Figure 35: Process Manufacturing: Information Systems

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Lesson: Elements, Functions, and Processing of a Process Order

Exercise 2: Integration with Planning; Process Order Creation with Planned Orders Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Execute an MRP planning run for your product • Interpret the result of the planning run in the stock/requirements list • Convert a planned order into a process order • Interpret the result of the planned order conversion in the stock/requirements list • Display a process order, navigate in the order, and name the structure and basic data

Business Example To find out how order-controlled production with process orders is integrated in supply chain planning, you execute an MRP run in the ECC system for your product T-FI1## Vanilla ice cream - packaged, starting with the existing planned independent requirements. You interpret the planning result in the stock/requirements list: Planned orders relating to the planned independent requirements are created by the planning run. You will then convert a planned order into a process order and interpret the results in the stock/requirements list. Finally, you will display the newly created process order and become familiar with the structure, navigation, and basic data in the order.

Task 1: 1.

Display the current stock/requirements list for your material T-FI1## in plant 1100. Describe the current situation:

Continued on next page

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Unit 2: Order-Controlled Production with Process Orders

Date

MRP Element

MRP Element Data

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Rec./ Reqd. qty

Available Qty

2.

Perform multilevel single-item planning for your material T-FI1## in plant 1100.

3.

After the planning run, display the current stock/requirements list. Describe the new situation after the planning run: Date

MRP element

MRP element Rec./ data Reqd. qty

Available Qty

Production version

Task 2: Display the planned orders from the stock/requirements list. 1.

In the “Header” view, write down the planned creation dates. Creation date for first planned order: ___________________________ Creation date for second planned order: ___________________________ Creation date for third planned order: ___________________________ Write down the production version selected: _______________

Continued on next page

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Lesson: Elements, Functions, and Processing of a Process Order

2.

Write down the responsible MRP controller given on the Assignment tab page. MRP Controller: ________________

3.

Display the material components from the BOM explosion for the planned order.

Task 3: 1.

In collective conversion, convert those planned orders within the area of responsibility of your MRP controller I## that have a planned opening date in the current week. Enter the following for planned order selection: Planning Plant:

1100

MRP Controller:

I##

Creation:

Time period of current week

Choose process order type PI01 for conversion. 2.

After planned order conversion, display the current stock/requirements list for material T-FI1##. Describe the new situation after planned order conversion: Date

MRP element

MRP element data

Rec./ Reqd. qty

Available Qty

Production version

Continued on next page

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Task 4: In change mode, call the new process order from the stock/requirements list. 1.

Get an overview of the process order structure and the data in the Header, Operations, and Materials views.

2.

Get an overview of the views in the order header. Write down the order number: __________________________ Pay attention to status management.

3.

Get an overview of the data in the following views, in particular: Header - General Data Pay attention to the quantity and date fields Header - Assignment Write down the production scheduler: ________________________ Header - Goods Receipt Note the option to define a batch number for product T-FI1##. Header - Master Data Write down the production version: ________________________ You can navigate in this view to the master recipe and to the BOM.

4.

Display the operation overview of the order. Compare the entries with the corresponding data in the master recipe. Get an overview of the detail views of a phase.

5.

Display the material list for your order. Compare the entries with the corresponding data in the master recipe. Note that the Batch field is ready for input for components that are to be managed in batches. Get an overview of the detailed data of a material component.

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Solution 2: Integration with Planning; Process Order Creation with Planned Orders Task 1: 1.

Display the current stock/requirements list for your material T-FI1## in plant 1100. Describe the current situation: Date

a)

MRP Element

MRP Element Data

Rec./ Reqd. qty

Available Qty

Logistic → Production process → MRP → evaluations → Stock / Requirements List Material:

T-FI1##

Plant:

1100

Enter Date

MRP MRP element element data

Rec./ Reqd. qty

Available qty

Today

Stock

Req. Date

IndReq

LSF

5000 -

5000 -

Req. Date

IndReq

LSF

5000 -

10000 -

Req. Date

IndReq

LSF

5000 -

15000 -

0

The quantity available today in the plant stock is 0 kg. There are 3 future planned independent requirements that are not yet covered by material requirements planning.

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2.

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Perform multilevel single-item planning for your material T-FI1## in plant 1100. a)

Logistic → Production process → MRP → Planning → Single item, multi-level Material:

T-FI1##

Plant:

1100

Choose Enter. The system displays a warning prompting you to check the input parameters. To start the planning run, choose Enter again. 3.

After the planning run, display the current stock/requirements list. Describe the new situation after the planning run: Date

MRP element

MRP element Rec./ data Reqd. qty

Available Qty

Production version

Continued on next page

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Date

a)

MRP element

MRP element Rec./ data Reqd. qty

Available Qty

Production version

Logistic → Production process → MRP → evaluations → Stock / Requirements List Material:

T-FI1##

Plant:

1100

Enter Date

MRP element

MRP element data

Today

Stock

Planned receipt

PLOrd

Number/Stck

5000

5000

Req. Date

IndReq

LSF

5000 -

0

Planned receipt

PLOrd

Number/Stck

5000

5000

Req. Date

IndReq

LSF

5000 -

0

Planned receipt

PLOrd

Number/Stck

5000

5000

Req. Date

IndReq

LSF

5000 -

0

Rec./ Reqd. qty

Available Proqty duction version 0 0001

0001

0001

As a result of the planning run, the system created planned orders to cover the planned independent requirements.

Task 2: Display the planned orders from the stock/requirements list. 1.

In the “Header” view, write down the planned creation dates. Creation date for first planned order: ___________________________ Creation date for second planned order: ___________________________ Continued on next page

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Creation date for third planned order: ___________________________ Write down the production version selected: _______________ a)

To display a planned order: Double-click the MRP element PLOrd., choose the Display Element (F7) icon Header tab page: Opening: Planned opening date The opening date is used as a selection criterion for the collective conversion of planned orders into process orders. Production Version: 0001

2.

Write down the responsible MRP controller given on the Assignment tab page. MRP Controller: ________________ Answer: Assignment tab page: MRP Controller: I##

3.

Display the material components from the BOM explosion for the planned order. a)

To display the components: Choose Components (F5)

Task 3: 1.

In collective conversion, convert those planned orders within the area of responsibility of your MRP controller I## that have a planned opening date in the current week. Enter the following for planned order selection: Planning Plant:

1100

MRP Controller:

I##

Creation:

Time period of current week

Continued on next page

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Lesson: Elements, Functions, and Processing of a Process Order

Choose process order type PI01 for conversion. a)

Logistic → Production process → Process order → Process order → Create → With Planned Orders Planning Plant:

1100

MRP Controller:

I##

Creation:

Time period of current week

Process Order Type:

PI01

Choose the Execute Selections (F8) icon. The Collective Conversion of Planned Orders: List screen appears. According to the selection criteria, the system only displays the planned order for material T-FI1## that is chronologically first. Select the corresponding line in the list and choose Convert. After the conversion, the system displays the number of the created process order in the lower message bar. To exit collective conversion, choose Back (F3). 2.

After planned order conversion, display the current stock/requirements list for material T-FI1##. Describe the new situation after planned order conversion: Date

MRP element

MRP element data

Rec./ Reqd. qty

Available Qty

Production version

Continued on next page

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Date

a)

MRP element

MRP element data

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Rec./ Reqd. qty

Available Qty

Production version

Logistic → Production process → Process Order → Environment → Stock/reqmts list Material:

T-FI1##

Plant:

1100

Enter Date

MRP element

Today

Stock

Planned receipt

PR-ORD Number/Stck

5000

5000

Req. Date

IndReq

LSF

5000 -

0

Planned receipt

PLOrd

Number/Stck

5000

5000

Req. Date

IndReq

LSF

5000 -

0

Planned receipt

PLOrd

Number/Stck

5000

5000

Req. Date

IndReq

LSF

5000 -

0

MRP element data

Rec./ Reqd. qty

Available qty

Production version

0 0001

0001

0001

The planned order has been converted into a process order.

Continued on next page

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Lesson: Elements, Functions, and Processing of a Process Order

Task 4: In change mode, call the new process order from the stock/requirements list. 1.

Get an overview of the process order structure and the data in the Header, Operations, and Materials views. a)

To call the process order in change mode: Double-click MRP element PR-ORD Choose the Change Element (F8) icon Choose the appropriate buttons to navigate.

2.

Get an overview of the views in the order header. Write down the order number: __________________________ Pay attention to status management. a)

3.

The order number varies.

Get an overview of the data in the following views, in particular: Header - General Data Pay attention to the quantity and date fields Header - Assignment Write down the production scheduler: ________________________ Header - Goods Receipt Note the option to define a batch number for product T-FI1##. Header - Master Data Write down the production version: ________________________ You can navigate in this view to the master recipe and to the BOM. a)

Header - Assignment Production Scheduler: I## Header - Goods Receipt The Batch field is ready for input. Header - Master Data Production Version: 0001

4.

Display the operation overview of the order. Compare the entries with the corresponding data in the master recipe. Continued on next page

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Get an overview of the detail views of a phase. a)

Choose Operations. Double-click the phase number to display the detail view of a phase.

5.

Display the material list for your order. Compare the entries with the corresponding data in the master recipe. Note that the Batch field is ready for input for components that are to be managed in batches. Get an overview of the detailed data of a material component. a)

Choose Materials. The Batch field is ready for input for components that are to be managed in batches. Double-click the item number to display the detailed data of a material component.

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Exercise 3: Process Order Release; Processing an Order with a PI Sheet Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Release a process order • Generate a control recipe for a process order • Edit a PI sheet • Send process messages • Check the results of order processing

Business Example You release your order for material T-FI1## and generate the control recipe for the order at the same time. You select and send your control recipe in the control recipe monitor. You edit the PI sheet. You select and send the process messages created while you were editing the PI sheet in the message monitor. After sending the messages, you check the current data in the process order, the stock/requirements list, and in inventory management.

Task 1: 1.

Release your process order for the production of material T-FI1## in collective processing. At the same time generate the control recipe for the order. Enter the following criteria for order selection: Order Type:

PI01

Plant:

1100

Production Scheduler:

I##

Continued on next page

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Do not enter any selection criteria for the release date (or set the selection period so that your order’s scheduled release date corresponds to the selection criteria). 2.

Display your process order now that it has been released and the control recipe has been generated. Find out which activities were performed when the order was released. Look at the order status. Note, in particular, the statuses REL, CRCR, BCRQ, BASC, and MACM. Header - Goods Receipt Note that a batch number was created automatically for the product T-FI1##. Material List Note that batch determination was executed automatically for material components subject to batch management requirement.

3.

Select your control recipe in the control recipe monitor. Send the control recipe and update the list display. Hint: In the manufacturing plant, control recipes are sent automatically in a job.

4.

Your control recipe destination is of the type PI sheet. Select and edit the PI sheet created when the control recipe was sent. Edit the PI sheet as specified in the solutions for this exercise.

5.

Select the process messages created by maintaining the PI sheet in the message monitor. Send the process messages. Hint: In the manufacturing plant, process messages are sent automatically in a job.

Task 2: Display the process order for material T-FI1##. 1.

On the Header Data screen, check the data for the quantity produced and the confirmed dates. Note the order statuses DLV and CNF. Continued on next page

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2.

Go to the Operation Overview and display the confirmed dates and calculated activities for some of the phases.

3.

Go to the Material List and display the quantities that have been issued for some of the materials.

Task 3: 1.

Display the current stock/requirements list for material T-FI1##. Describe the new situation: Date

2.

2009

MRP element

MRP element data

Receipt/requirement

Available quantity

Production version

Display the stock overview for material T-FI1##.

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Solution 3: Process Order Release; Processing an Order with a PI Sheet Task 1: 1.

Release your process order for the production of material T-FI1## in collective processing. At the same time generate the control recipe for the order. Enter the following criteria for order selection: Order Type:

PI01

Plant:

1100

Production Scheduler:

I##

Do not enter any selection criteria for the release date (or set the selection period so that your order’s scheduled release date corresponds to the selection criteria). a)

Logistics → Production - Process → Process Order → Process Order → Release Order Type:

PI01

Plant:

1100

Production Scheduler:

I##

Delete the entries in the fields for date selection. Choose the Execute Selections (F8) icon. The Release Process Order: List screen appears. In accordance with the selection criteria, the system only displays the process order you opened above for material T-FI1##. Choose Control Recipe (Release with Control Recipe Generation). After you have released the order and the control recipe has been generated, choose Back (F3) to exit the list. 2.

Display your process order now that it has been released and the control recipe has been generated. Find out which activities were performed when the order was released. Continued on next page

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Lesson: Elements, Functions, and Processing of a Process Order

Look at the order status. Note, in particular, the statuses REL, CRCR, BCRQ, BASC, and MACM. Header - Goods Receipt Note that a batch number was created automatically for the product T-FI1##. Material List Note that batch determination was executed automatically for material components subject to batch management requirement. a)

Logistics → Production - Process → Process Order → Process Order → Display Process order: Order number Enter The following activities were performed: Order release:

See status REL “Order Released”

Control recipe generation:

See status CRCR “Control Recipe Created”

Creation of batch master record for product T-FI1##: See status BASC “Batch Assignment Complete” See the automatically created batch number in the header data screen Goods receipt Material availability check: See status MACM “Material Confirmed” Batch determination for material components subject to a batch management requirement: See automatically assigned batch in the material list. 3.

Select your control recipe in the control recipe monitor.

Continued on next page

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Send the control recipe and update the list display. Hint: In the manufacturing plant, control recipes are sent automatically in a job. a)

Logistics → Production - Process → Process Management → Control Recipe → Control Recipe Monitor Plant:

1100

Process order:

Order number

or Plant:

1100

Destination Address:

GRP. ## ICE

After you choose Enter, the Monitor for Control Instructions/Recipes screen appears. The control recipe status is Created. Select your control recipe and choose Send. After sending, choose the Refresh icon to update the list. The control recipe must now have the status Sent. 4.

Your control recipe destination is of the type PI sheet. Select and edit the PI sheet created when the control recipe was sent.

Continued on next page

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Edit the PI sheet as specified in the solutions for this exercise. a)

(...) → Process Management → PI Sheet → Find or (...) → Process Management → PI Sheet → Worklist - Maintain Choose appropriate selection criteria, for example: Plant:

1100

Operating group:

GRP. ## ICE

Execute (F8) Maintain PI Sheet (F5) Enter your signature to report the start of PI sheet maintenance. Sign with your SAP ECC user name and confirm the signature with your SAP ECC password. The material component to be entered for the first phase 1010 can be found in the list of ingredients. The quantities and batch numbers from the process order are set as default values. The line operator can change these values. Enter your signature to report the end of phase 1010. Edit the other phases of the PI sheet in the same manner. In the last phase at the end of the PI sheet, report the number of ice cream packages produced. Enter your signature to report the end of the PI sheet. Save your entries. 5.

Select the process messages created by maintaining the PI sheet in the message monitor.

Continued on next page

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Send the process messages. Hint: In the manufacturing plant, process messages are sent automatically in a job. a)

(...) → Process Management → Message → Message Monitor Plant:

1100

Process order:

Order number

After you choose Enter, the Monitor for Process Messages: Selected New Messages screen appears. Select all process messages and choose Send Messages to send them. After sending, choose Refresh to update the list. The messages must now all have the status Sent.

Task 2: Display the process order for material T-FI1##. 1.

On the Header Data screen, check the data for the quantity produced and the confirmed dates. Note the order statuses DLV and CNF. a)

(...) → Process Order → Display Process order: Order number After pressing Enter, the order header appears. The produced quantity and confirmed order dates are displayed here in the General Data. After the PI sheet has been edited completely, the statuses DLV Delivered and CNF Confirmed are set.

2.

Go to the Operation Overview and display the confirmed dates and calculated activities for some of the phases. a)

Choose Operations. Select one or more phases and double-click a phase number. To display the confirmed dates, choose the Dates tab page. To display the activities calculated from the dates, choose the Qty/Activities tab page. You can choose Previous Operation and Next Operation to go to the dates of the individual phases. Continued on next page

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Lesson: Elements, Functions, and Processing of a Process Order

3.

Go to the Material List and display the quantities that have been issued for some of the materials. a)

Choose Materials. Select one or more material components (and the individual batch records for the materials subject to batch management requirement) and double-click an item number. The General Data screen contains the component quantities withdrawn.

Task 3: 1.

Display the current stock/requirements list for material T-FI1##. Describe the new situation: Date

MRP element

MRP element data

Receipt/requirement

Available quantity

Production version

Continued on next page

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Date

a)

MRP element

MRP element data

TSCM42

Receipt/requirement

Available quantity

Production version

Logistics → Production - Process → Process Order → Environment → Stock/Requirements List Material:

T-FI1##

Plant:

1100

Enter Date

MRP element

MRP element data

Receipt/requirement

Available quantity

Today

Stock

Req. date

PIR

LSF

5000 -

0

Plnd Receipt

Plnd Ord.

Number / Stck

5000

5000

Req. date

PIR

LSF

5000 -

0

Plnd Receipt

Plnd Ord.

Number / Stck

5000

5000

Req. date

PIR

LSF

5000 -

0

Production version

5000

0001

0001

After receipt of the goods, the process order no longer appears in the list. The plant stock was raised by the delivered quantity.

Continued on next page

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Lesson: Elements, Functions, and Processing of a Process Order

2.

Display the stock overview for material T-FI1##. a)

Logistics → Materials Management → Inventory Management → Environment → Stock → Stock Overview Material:

T-FI1##

Plant:

1100

Program → Execute The batch you produced is in storage location 0001 “Delivery Warehouse” in plant 1100. Due to a corresponding setting in the material master, the batch is first classified as stock in quality inspection.

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Lesson Summary You should now be able to: • Describe the individual steps in process order management • Describe the concept of process management and use a PI sheet to execute a process order • Explain the special functions for process order management in the pharmaceutical area

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Unit Summary

Unit Summary You should now be able to: • Explain the characteristics of order-controlled production with process orders • Describe the individual steps in process order management • Describe the concept of process management and use a PI sheet to execute a process order • Explain the special functions for process order management in the pharmaceutical area

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Unit Summary

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Test Your Knowledge

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Test Your Knowledge 1.

Name some application areas for process orders.

2.

Name some basic functions of the process order.

3.

Name the master data for the process order.

4.

Name the main steps in the processing of a process order.

5.

Name some of the functions for mapping a GMP-compliant production.

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Answers 1.

Name some application areas for process orders. Answer: • • • • •

2.

Production by customer request Make-to-order production Batch production Production campaigns Mass production

Name some basic functions of the process order. Answer: • • • • • • • • • • • • • •

3.

Status management Production by production versions Scheduling Calculation of capacity requirements Costing Batch number assignment Manufacture of co-products Availability checks Material quantity calculation Active ingredient management Batch determination Resource network Resource selection Printing of order papers

Name the master data for the process order. Answer: • • •

86

Material master records and batch master records (integration with batch management) Resources Production versions with master recipes and material BOMs

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Test Your Knowledge

4.

Name the main steps in the processing of a process order. Answer: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

5.

Order request Process order creation Availability check Resource/line scheduling Resource selection Batch determination Material quantity calculation Process order release Order printing Send control recipes Edit PI sheet Process messages to various destinations Material staging/material withdrawals Order confirmations In-process quality checks Goods receipts Variance calculation Process order settlement Batch record Archive/delete

Name some of the functions for mapping a GMP-compliant production. Answer: • • • • • • • • •

2009

Material reconciliation Digital signature Material identification Approved recipe Approved process order Batch record Approved inspection plan Quality management Batch management

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Unit 3 Repetitive Manufacturing

85

To find out how the exercises fit into the course from a timing point of view, see the proposal in the instructor guide.

Unit Overview In this unit, you will learn about repetitive manufacturing.

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

Explain the characteristics of period-based repetitive manufacturing Describe the main steps in repetitive manufacturing Evaluate the main functions within repetitive manufacturing

Unit Contents Lesson: Characteristics of Repetitive Manufacturing ....................... 90 Exercise 4: Master Data - Optional ....................................... 99 Lesson: Functions and Process Steps in Repetitive Manufacturing .....109 Exercise 5: Integration with Production Planning and MRP in the ECC System .......................................................................123 Exercise 6: Line Loading Planning in the ECC System ...............131 Exercise 7: Material Staging and Backflush ............................137

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Lesson: 86

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Characteristics of Repetitive Manufacturing Lesson Duration: 40 Minutes

Lesson Overview The following topics are dealt with in this lesson: • •

Application areas and characteristics of repetitive manufacturing Functional flow

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

Explain the characteristics of period-based repetitive manufacturing

For demonstrations and instructor notes, see the instructor guide on the SAP Corporate Portal.

Business Example Your company manufactures products in large numbers. The production is quantity-based and period-based. You belong to the team that implements repetitive manufacturing within the SAP implementation project. For this purpose, you must implement the entire process chain for in-house production, which allows your company to organize, control, and execute production based on SAP functions.

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Application Areas

Figure 36: Application Areas

Repetitive manufacturing is mainly used for production scenarios with high product stability, high repetition rates, and low product complexitity.

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General Characteristics

Figure 37: Period-based Repetitive Manufacturing: Characteristics (1)

Figure 38: Period-based Repetitive Manufacturing: Characteristics (2)

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Cross-Application Process Flow

Figure 39: Cross-Application Process Flow

The complex process chain from independent requirements to the goods issue of the finished product is modeled in a lean version in repetitive manufacturing. Typical features are, for example, the use of planned orders for production (planned orders are not converted to production orders. They only obtain the new order type of the “run schedule quantity” (RSQ) when the production version is assigned) as well as the confirmation of the finished product with simultaneous backflushing of the components used.

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Logistical Master Data for Repetitive Manufacturing

Figure 40: Master Data for Repetitive Manufacturing

To allow the material to be used in repetitive manufacturing, you set the Repetitive Mfg indicator in the material master (in the MRP view). This means that you can use all the various production versions of this material for repetitive manufacturing (that is, you can set the Repetitive Mfg allowed for version indicator in the production version). The BOM defines the planned material consumption for the components. When you backflush components in repetitive manufacturing, you can define the issue storage location from which components are to be backflushed in the status/long text of the BOM item (Production storage location field). Production lines are usually created as simple work centers in the ECC system. In the work center, you define the availability of the production line. The production line created as the work center is entered in the Production line field in the production version. This same work center is specified in the single operation of the routing. Production lines that have more than one work center can be represented in a line hierarchy. In repetitive manufacturing, the routing defines the production rate (quantity per time unit) used to produce materials on production lines. The production quantities and their capacity requirements are scheduled and calculated respectively according to the production rate. Therefore, the routing provides the basis for lead time scheduling. In repetitive manufacturing, routings are not normally used to describe the actual operations to be performed. For this reason, routings in repetitive manufacturing often have just one operation. The total production rate

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Lesson: Characteristics of Repetitive Manufacturing

of the line is specified in this operation. It defines how many materials per time unit can be produced on this production line. In the single operation, you enter the production line created as the work center. There are two different routings available in the ECC system: Standard routings and rate routings. Rate routings are specially designed for the needs of repetitive manufacturers and can be used instead of standard routings for organizational purposes. However, you can also use standard routings for repetitive manufacturing.

Demo Scenario: PC Production in the Dresden Plant

Figure 41: Demo Scenario: PC Production in the Dresden Plant

Demonstration example for repetitive manufacturing: PCs and PC assemblies are produced in plant 1200. The most important material numbers used for the demonstrations and exercises in the training system are: T-F10## PC Maxitec R-375 T-B10## Motherboard 375 T-B20## Cable with grounded plug T-B30## Keyboard T-B40## TFT screen T-B50## Disk drive

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T-B60## Hard disk T-B70## Casing T-B80## CD-ROM T-B90## Modem T-T6##

Memory (for pull list: Direct transfer posting)

T-TE##

Processor M-375

Production lines:

96

T-L1##

Production line 1 (for production of T-F10##)

T-L3##

Production line 3 (for production of T-B10##)

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Lesson: Characteristics of Repetitive Manufacturing

Facilitated Discussion Understand application areas and characteristics of repetitive manufacturing.

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions. Name some important characteristics of repetitive manufacturing and discuss possible applications.

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Lesson: Characteristics of Repetitive Manufacturing

Exercise 4: Master Data - Optional Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Name the essential master data required for repetitive manufacturing • Explain what is special about the master data for repetitive manufacturing

Business Example You work for a company that uses repetitive manufacturing to produce PCs on two production lines. You are a member of the SAP SCM project team responsible for implementing the functions of Repetitive Manufacturing. Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you look at the master data for the PC T-F10## (material master, BOM, routing, and work center as well as the product cost collector from Controlling).

Task 1: First, get an overview of the menu structure for the repetitive manufacturing functions. 1.

Which menu path takes you to the Repetitive Manufacturing menu?

2.

Which transaction takes you to Customizing for Repetitive Manufacturing? ________________________________________________________________

3.

List the Logistics master data used for repetitive manufacturing. ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ Continued on next page

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________________________________________________________________

Task 2: In the logistics folder in the SAP ECC menu, navigate to the Material Master of PC T-F10## (## represents your group number) and go to the MRP 4, plant 1200 view. Use the change mode (transaction MM02). 1.

Name three material master settings that are specific to repetitive manufacturing. ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

2.

Display production version 0001. Check the consistency of the combination of BOM and routing by choosing Check.

3.

Which production line is entered in production version 0001? ________________________________________________________________

4.

Write down the task list group of the rate routing entered. ________________________________________________________________

Task 3: 1.

Check the material BOM for material T-F10## in the Logistics master data. How many assemblies are on the hierarchy level directly below the finished product? ________________________________________________________________

Task 4: Display the rate routing for material F10##, plant 1200 in the Logistics master data. 1.

How many different routings are displayed in the overview? ________________________________________________________________

Continued on next page

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2.

Select the first routing with group counter 1 and choose Operations. What is special about the routing?

3.

Name the work center involved and the production rate planned.

4.

Exit the operation overview and go back to the rate routing overview. Which work center belongs to group counter 2?

5.

Write down the task list group number and compare it with task 2.4. Hint: The task list group number is displayed in the header data of the rate routing. ________________________________________________________________

6.

Does production version 0001 enable repetitive manufacturing with the two routings? Give reasons. ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

Continued on next page

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Task 5: In the Repetitive Manufacturing menu, check in the master data whether a product cost collector already exists for material T-F10## in plant 1200. Hint: Note: To do this, you must activate the field for the material in the display transaction. 1.

How many product cost collectors exist and how are they assigned? ________________________________________________________________

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Solution 4: Master Data - Optional Task 1: First, get an overview of the menu structure for the repetitive manufacturing functions. 1.

Which menu path takes you to the Repetitive Manufacturing menu? Answer: The Repetitive Manufacturing menu is in the Production folder. SAP Menu → Logistic → Production → Repetitive Manufacturing The main master data is also available in the Production folder: SAP Menu → Logistic → Production → Master Data

2.

Which transaction takes you to Customizing for Repetitive Manufacturing? ________________________________________________________________ a)

SAP Menu → Tools → Customizing → IMG → Edit project Transaction: SPRO SAP Reference IMG → Production → Repetitive Manufacturing You can branch directly to Customizing for Repetitive Manufacturing using transaction OPP3.

3.

List the Logistics master data used for repetitive manufacturing. ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ a)

Logistics master data: • • • •

Material master BOM Routing Work center (line)

Task 2: In the logistics folder in the SAP ECC menu, navigate to the Material Master of PC T-F10## (## represents your group number) and go to the MRP 4, plant 1200 view. Use the change mode (transaction MM02). 1.

Name three material master settings that are specific to repetitive manufacturing. Continued on next page

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________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ a)

SAP Menu → Logistic → Production → Master data → Material Master → Material → Change → Immediately Material

T-F10##

View

MRP 4

Plant

1200

The three settings are: 1. 2. 3. 2.

Repetitive mfg indicator Repetitive manufacturing profile Production version

Display production version 0001. Check the consistency of the combination of BOM and routing by choosing Check. a)

On the detail view for the production version, choose “Check” in the top right-hand corner. The consistency check has the following results: BOM and routing exist. There are no error messages. Exit the screen by choosing “Cancel”.

3.

Which production line is entered in production version 0001? ________________________________________________________________ a)

4.

From the detail screen, you can see that production version 0001 contains production line T-L1##.

Write down the task list group of the rate routing entered. ________________________________________________________________ a)

The number varies. On the detail screen of the production version, the Task list group is also displayed in the Rate-based planning line under Planning data.

Task 3: 1.

Check the material BOM for material T-F10## in the Logistics master data. Continued on next page

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How many assemblies are on the hierarchy level directly below the finished product? ________________________________________________________________ a)

SAP Menu → Logistic → Production → Master data → Bills of material → BOM → Material BOM → Display Material

T-F10##

Plant

1200

Usage

1

The Asm assembly indicator is set for 3 BOM items.

Task 4: Display the rate routing for material F10##, plant 1200 in the Logistics master data. 1.

How many different routings are displayed in the overview? ________________________________________________________________ a)

SAP Menu → Logistic → Production → Master data → Routings → Routings → Rate routings → Display Material

T-F10##

Plant

1200

Key date

Today

→ Routings or Return Two routings exist (two group counters). 2.

Select the first routing with group counter 1 and choose Operations. What is special about the routing? Answer: In the rate routing overview, select the line with group counter and choose Operations. The special feature here is that there is only one operation.

3.

Name the work center involved and the production rate planned. Answer: The work center contains the (entire) T-L1## line and the production rate (30 pieces per hour).

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4.

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Exit the operation overview and go back to the rate routing overview. Which work center belongs to group counter 2? Answer: Choose Goto → Header overview. In the routing overview, select the line with group counter and choose Operations. The work center used in the second routing is T-L2##. ((Note: Nothing will be produced at this work center in the following exercises.)

5.

Write down the task list group number and compare it with task 2.4. Hint: The task list group number is displayed in the header data of the rate routing. ________________________________________________________________ a)

Select a line in the routing overview and choose “Header ”. The task list group number is the same as the one in exercise 2.4.

6.

Does production version 0001 enable repetitive manufacturing with the two routings? Give reasons. ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ a)

Production version 0001 only allows production according to the routing with group counter 1 since the group counter is taken over to the production version for a more detailed specification of the routing.

Task 5: In the Repetitive Manufacturing menu, check in the master data whether a product cost collector already exists for material T-F10## in plant 1200. Hint: Note: To do this, you must activate the field for the material in the display transaction. 1.

How many product cost collectors exist and how are they assigned?

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________________________________________________________________ a)

SAP Menu → Logistic → Production → Repetitive manufacturing → Master data → Product Cost Collector → Process Product Cost Collector Material

T-F10##

Plant

1200

Select material T-F10## in the left part of the screen. Two product cost collectors already exist. They are assigned to the material by means of the production version (one product cost collector for each production version).

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Lesson Summary You should now be able to: • Explain the characteristics of period-based repetitive manufacturing

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Lesson: 103

Lesson: Functions and Process Steps in Repetitive Manufacturing

Functions and Process Steps in Repetitive Manufacturing Lesson Duration: 115 Minutes

Lesson Overview In this lesson, you will familiarize yourself with the essential functions and standard process steps in repetitive manufacturing.

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

Describe the main steps in repetitive manufacturing Evaluate the main functions within repetitive manufacturing

For demonstrations and instructor notes, see the instructor guide on the SAP Corporate Portal.

Business Example Important stages of repetitive manufacturing include the dispatching of quantities to the production lines, material staging of the components, confirmation of quantities produced, and settlement of the cost collector. These functions are integrated with other areas in your company, such as controlling and warehouse management. Therefore, you must consider the many integration relationships when implementing repetitive manufacturing.

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Repetitive Manufacturing: Process Flow

Figure 42: Repetitive Manufacturing: Process Flow

Despite a streamlined implementation of basic functions, a wide range of activities is possible in repetitive manufacturing. Important aspects are planning of line loading and (generally simultaneous) capacity monitoring. You can, for example, use the planning table (multi-level access) to check the availability of assemblies for the finished product. The worker gets the information he or she needs from the operational method sheet (a description of the operation is possible if required) and from the production list (materials, quantities, and dates). Material staging is performed using stock transfers or KANBAN staging to the line. During production, a reporting point confirmation can be used to determine the work in progress. After production processing, the finished product is confirmed to stock. This means both the goods receipt and the component backflush are posted. A product cost collector looks after cost accounting.

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Planning in Repetitive Manufacturing

Figure 43: Planning in Repetitive Manufacturing

The SAP SCM application offers two general solutions to integrating planning and production: • •

Planning with the functions belonging to the APO component (contained in the SCM system) Planning with the functions belonging to the MRP component (contained in the ECC system)

Production preparation, execution, and control are always performed with the functions of the ECC component, but dependent dependent on the production type. These functions include costing, material staging, confirmation, goods movements, and settlement. The master data and transaction data (planned orders, purchase requisitions, purchase orders, stocks, and so on) is usually exchanged between the SAP ECC and SCM (APO) components using the “Core Interface” (CIF). Specific events (for example, confirmation or goods receipt) trigger the transfer of data from ECC to SCM-APO and vice versa.

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Planned orders can be generated by material requirements planning in ECC using MRP, or in SCM (APO), with the following applications: •

•

Supply Network Planning as part of planning in APO (SNP). This component supports cross-plant planning in a long-term planning horizon across the whole supply and procurement chain. Stock transport requisitions (distribution), planned orders (in-house production), and purchase requisitions (external procurement) are generated for each production plant. Production Planning and Detailed Scheduling as part of APO planning (PP/DS). This generates planned orders and purchase requisitions in a defined, short-term time period (production horizon) in the production plant.

A distinguishing feature of repetitive manufacturing is that planned orders with order type “RSQ” (run schedule quantity) are used for production. This means that planned orders are not converted. Only the order type changes when the planned order is assigned to the production line.

Line Loading

Figure 44: Overview: Planning Line Loading

Within the two planning systems SAP ECC and SAP SCM (APO), you can use any of the following four options to plan line loading (dispatching planned orders on the production line): Alternative selection in ECC: If there is only one valid production version, for example, if only one line is available, you can set the “Alternative selection” indicator to 2 in the material master (MRP 4 view). Planned orders are then

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automatically assigned to this line. If several lines are available, the system assigns the first line it finds. Since this reduces your freedom when planning line loading, we recommend that you only use this option when only one valid production version or production line is available. Quota arrangement:If several production lines are available but one is preferred (always to be loaded to full capacity, for example), you can use quota arrangements to distribute the remaining quantity to the alternative lines. To do this, you maintain the “Quota arr. usage” field in the MRP2 view and trigger quota maintenance in the MRP menu under master data. We generally recommend that you only use quota arrangements for rough-cut planning and that you also carry out postprocessing, for example, with the ECC planning table or the APO product planning table. ECC planning table/APO planning table (in the SCM system): In contrast to the methods listed above, quantities are essentially dispatched manually on the available lines when planned orders are assigned or reassigned in the ECC planning table or the APO planning table. Using APO heuristics (in the SCM system) for repetitive manufacturing: If you use the APO heuristics for repetitive manufacturing (REM heuristics) in the SCM system, the three steps of quantity planning, line loading planning, and capacity planning can be combined and executed automatically. This option is not available in ECC.

Figure 45: Actions for Manual Planning of Line Loading (Example: ECC)

The planner uses the ECC planning table to process the master production schedule. They can check the production quantities at a glance, change them if required, and create new production quantities (planned orders). The work scheduler can also determine the capacity load utilization of the production line

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and the availability of the products. In addition, he or she can display the source of the capacity requirements (pegged capacity) by double-clicking the capacity requirements. Since planning in repetitive manufacturing is based on quantities and periods, the display in the planning table is quantity-based and period-based. You can choose any planning period (shift, day, week, month, planning calendar period). In assignment mode, the planner can assign the production quantities (planned orders) to a production version and thus also to a production line. If this has already been done in MRP, he or she can also change existing assignments. Planned orders that are assigned manually to a line are assigned the order type PE (run schedule quantity) in repetitive manufacturing and are usually firmed. With the repetitive manufacturing profile, the firming behavior can be limited to the planning time fence for each material or deactivated for all orders. In addition, you can choose Materials Overview to go to a separate material overview that displays the exception message and days’ supply situation. Changes you make in the planning table are not written to the database unless you save them. In the SCM system, similar functions are available in the APO product planning table. This is an enhancement of the ECC planning table with enhanced APO planning functions and is used as a tool for manual planning in the SCM system. The figure above shows the basic structure of the ECC planning table. To illustrate the APO product planning table, the terms “Material” and “Line/Capacity” would have to be replaced by the terms “Product” and “Resource” in the graphic above.

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Material Staging Options

Figure 46: Material Staging Options

The ECC system uses various methods to control material staging. • • •

Warehouse management with the component MM-IM (Inventory Management) Replenishment control with the KANBAN component Storage location management and replenishment control with the component LE-WM (Warehouse Management System)

The pull list enables processing using transfer postings at storage location level, supports event-controlled KANBAN, and allows you to integrate Warehouse Management (WM). Since pick part processing is order-based, the Warehouse Management system prefers to use release order parts for non order-based repetitive manufacturing. Release order parts are ordered manually. In this case, the required quantity is calculated from the target quantities of the components in the selected orders that have been released. Both pick part processing and crate part processing can be used when the typical repetitive manufacturing functions (such as the planning table) are used for production orders.

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Confirmation and Goods Receipt

Figure 47: Confirmation and Goods Receipt

You can use a BAPI interface for confirmations from PDC systems. A separate transaction (MFBF) is available for entering confirmations manually in the ECC system.

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When you post the goods receipt for the finished parts during confirmation, a number of different actions are performed by default (these are controlled to a large extent using the repetitive manufacturing profile): • • • • • •

Goods issue posting of the components used (usually by backflushing) Statistics update in the Logistics Information System (LIS) or the Business Information Warehouse (BW) Reduction of run schedule quantities/planned orders and the associated capacity requirements on the production lines Posting of production costs incurred (material costs, production activities, overhead costs) to a product cost collector Creation of a data entry document Other optional actions (see the "Details" button in the confirmation transaction) include taking account of the setup costs for lot size-independent material quantities, posting component/assembly scrap, collective entry for different materials in a line, archiving confirmation documents, goods issue confirmation only or activity confirmation only (more/less activity), reporting point confirmations, decoupled confirmation processes, aggregation, and various postprocessing and reversal options. In addition, sales-order based production enables confirmation with reference to sales orders.

Reporting Point Confirmation

Figure 48: Reporting Point Confirmation

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Scenario: You have a long production line with a long lead time. However, the goods issues for the first components at work centers 1-1 and 1-2 are to be posted on-time and not by backflushing with final confirmation at the end of the production line. All components used along the production line are usually backflushed during final confirmation. If there are long lead times, the goods issues for the components may be posted much later in the system than when they are actually physically withdrawn. In this case, it makes sense to use reporting point confirmation to post the withdrawal of components (and production activities) at an earlier stage after operations already completed. The above example contains the 3 reporting points that are linked to operations 10 (work center 1-1), 20 (work center 1-2), and 40 (work center 1-4). Prerequisites: In addition to activating reporting point confirmation in the repetitive manufacturing profile, you must ensure that the relevant work centers exist and that the operations are available in the routing and defined as reporting points using the control key. Depending on the application, you can and should use optional or mandatory reporting point confirmation.

Cost Debit/Credit (Product-Related Cost Object Controlling)

Figure 49: Cost Debit/Credit (Product-Related Cost Object Controlling)

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Settlement in repetitive manufacturing is always period-based and based on the costs in the product cost collector (product-related cost object controlling). During confirmation in repetitive manufacturing, the material costs for the components and the production activities (only if a material cost estimate with price update has been carried out in advance) are automatically posted to the product costs collector during backflushing. The product cost collector is debited with the material costs and production activities (in the repetitive manufacturing profile, you can define whether the actual data entry of the activities is to be made with reference to the material cost estimate or the version-specific cost estimate). In addition, during confirmation, the product cost collector is credited with the valuation price (materials controlled with standard price) or with the moving average price of the assembly (materials controlled with the moving average price). Overheads are not determined with reference to an operation (that is, not for each goods movement or activity confirmation). Rather, they are determined periodically during period-end closing in Controlling using an overhead structure and are posted to the product cost collector. You can use a separate transaction in the Repetitive Manufacturing menu for this. Different components to the planned components may be used in production or the overhead cost rates may change. This results in variances in the product cost collector, and a settlement must be carried out. The aim of the settlement is to credit the product cost collector in full. During settlement, the costs not yet credited to the product cost collector are transferred. For a material that is valuated using the standard price, the variant costs are posted to the price difference account.

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Integration with Controlling

Figure 50: Integration with Controlling

Transaction codes for the above actions: • • •

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Create product cost collector for each material (KKF6N), as well as for each production version (KKF6M) Material cost estimate [CK11N] with price update (marking and release) [CK24] Preliminary cost estimate ([MF30] and [OPP3], REM profile)

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Repetitive Manufacturing: Information Systems

Figure 51: Repetitive Manufacturing: Information Systems

Repetitive manufacturing supports different evaluation methods. In addition to analyses that use CO reports, data is updated to the Logistics Information System LIS by default (exception: planning data must be updated manually or in a background job). A connection to the Business Information Warehouse (BW) is also standard. Evaluations based on orders are not supported because the processing is not order-related.

Repetitive Manufacturing: Extended Scope of Functions Apart from the basic functions, repetitive manufacturing provides several other functions (see next section). Course SCM320 provides detailed information about the most important of these functions.

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Figure 52: Period-Based Repetitive Manufacturing: Additional Functions

An connection to Microsoft Office is provided for printing shop papers and quantity papers (not shop floor papers): You can use Microsoft Word to print operational method sheets, and Microsoft Excel to print production lists. In addition to make-to-stock production, make-to-order repetitive manufacturing is also supported. This enables you to handle configurable materials, for example. To determine the work in process or to post component withdrawals more promptly, you can use a reporting point procedure (only for make-to-stock production). In terms of configurable materials, action control enables actions to be triggered automatically (for example, printing the component list). The modelling of takts, along with the sequence planning it involves, is mapped by a separate function: “takt-based flow manufacturing”. Repetitive manufacturing supports handling unit management, in which goods and packaging are mapped as a logistic unit. Serial number assignment for unique identification is also possible in repetitive manufacturing.

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Exercise 5: Integration with Production Planning and MRP in the ECC System Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Create a quantity-based and period-based master production schedule for repetitive manufacturing • Interpret the results of a planning run in the stock/requirements list

Business Example You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the PCs are planned at the finished product level and produced according to the planning program. Using this method, sales orders influence requirements and are charged against planning. First, check whether the master data for materials T-F10## (PC) and T-B10## (motherboard) is correct and then create planned independent requirements.

Task: 1.

Make sure that the strategy group has been set correctly in the ECC material master for the finished product T-F10## (plant 1200, MRP 3 view): 40 – planning without final assembly:

2.

Are the materials T-F10## (the PC) and T-B10## (the motherboard) permitted for repetitive manufacturing? _______________________________________________________ Hint: In the material master, check the settings in the MRP 4 view and the release indicator (“REM” allowed) in the relevant production versions.

3.

Now enter planned independent requirements for the finished product. Menu path: Logistic → Production → Production Planning → Demand Management → Planned independent requirement → Create

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Data:

Values:

Material

T-F10##

Plant

1200

Planning Period

W

On the next screen, choose the Sched. Lines tab. Create a planned independent requirement with a requirements date for next week (enter the calendar week in the format week.year). The planned quantity should be 600 pieces. The quantity with period indicator W is to be distributed over the individual working days. Therefore, set the indicator to T (day format) in the Splt column and confirm your entry. Confirm any warning messages that may be displayed and save your planned independent requirements. 4.

The Sales department receives a sales order. Assume the role of a Sales employee and create the following sales order for finished product T-F10##: Menu path: Logistic → Sales and Distribution → Sales → Order → Create Data:

Values:

Order Type

TA

Sales Organization

1000

Distribution Channel

10

Division

00

Sold-to party

1171

PO Number

660##

Requested delivery date

In two weeks time – on Tuesday

Material

T-F10##

Quantity

100 pieces

Confirm potential information messages and accept the result of the availability check carried out in the background with “Continue”. Save the sales order. 5.

Plan the PC’s BOM structure using an MRP run. Menu path: Continued on next page

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Logistic → Production → MRP → Planning → Single-item, multi-level planning Use the following settings: Material

T-F10##

Plant

1200

Additional settings

2, 3, 1, 1, 1

Press “Enter” twice to start the run. Hint: Multi-level planning ensures that dependent requirements are also generated for lower hierarchy levels in the BOM. 6.

Interpret the results using the current stock/requirements list for finished product T-F10## in plant 1200: Menu path: Logistic → Production → MRP → evaluations → Stock / Requirements List Does a consumption take place? _______________________________________________________ _______________________________________________________

7.

Interpret the results using the current stock/requirements list for assembly T-B10## in plant 1200: Menu path: Logistic → Production → MRP → evaluations → Stock / Requirements List

8.

Double-click a planned order to display the detail data. Why are there no pushbuttons to convert the planned order into a production order? _______________________________________________________ _______________________________________________________

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Solution 5: Integration with Production Planning and MRP in the ECC System Task: 1.

Make sure that the strategy group has been set correctly in the ECC material master for the finished product T-F10## (plant 1200, MRP 3 view): 40 – planning without final assembly: a)

SAP standard menu → Logistic → Production → Master data → Material Master → Material→ Change → Immediately Material

T-F10##

Plant

1200

You must enter and save strategy group 40 (for planning and final assembly). 2.

Are the materials T-F10## (the PC) and T-B10## (the motherboard) permitted for repetitive manufacturing? _______________________________________________________ Hint: In the material master, check the settings in the MRP 4 view and the release indicator (“REM” allowed) in the relevant production versions. a)

SAP standard menu → Logistic → Production → Master data → Material Master → Material → Display → Display current 1. 2.

3.

Check whether the Repetitive Manufacturing indicator is set in the “MRP 4” view. It has been set. Check the existing production versions: Is the repetitive indicator set? Answer: Yes.

Now enter planned independent requirements for the finished product. Menu path: Logistic → Production → Production Planning → Demand Management → Planned independent requirement → Create

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Data:

Values:

Material

T-F10##

Plant

1200

Planning Period

W

On the next screen, choose the Sched. Lines tab. Create a planned independent requirement with a requirements date for next week (enter the calendar week in the format week.year). The planned quantity should be 600 pieces. The quantity with period indicator W is to be distributed over the individual working days. Therefore, set the indicator to T (day format) in the Splt column and confirm your entry. Confirm any warning messages that may be displayed and save your planned independent requirements. a) 4.

–

The Sales department receives a sales order. Assume the role of a Sales employee and create the following sales order for finished product T-F10##: Menu path: Logistic → Sales and Distribution → Sales → Order → Create Data:

Values:

Order Type

TA

Sales Organization

1000

Distribution Channel

10

Division

00

Sold-to party

1171

PO Number

660##

Requested delivery date

In two weeks time – on Tuesday

Material

T-F10##

Quantity

100 pieces

Confirm potential information messages and accept the result of the availability check carried out in the background with “Continue”. Save the sales order. a) 5.

Plan the PC’s BOM structure using an MRP run. Continued on next page

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Menu path: Logistic → Production → MRP → Planning → Single-item, multi-level planning Use the following settings: Material

T-F10##

Plant

1200

Additional settings

2, 3, 1, 1, 1

Press “Enter” twice to start the run. Hint: Multi-level planning ensures that dependent requirements are also generated for lower hierarchy levels in the BOM. a) 6.

–

Interpret the results using the current stock/requirements list for finished product T-F10## in plant 1200: Menu path: Logistic → Production → MRP → evaluations → Stock / Requirements List Does a consumption take place? _______________________________________________________ _______________________________________________________ a)

SAP standard menu → Logistic → Production → MRP → evaluations → Stock / Requirements List Material

T-F10##

Plant

1200

Yes, the sales order consumes an IndReq. 7.

Interpret the results using the current stock/requirements list for assembly T-B10## in plant 1200: Menu path:

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Logistic → Production → MRP → evaluations → Stock / Requirements List a)

SAP standard menu → Logistic → Production → MRP → evaluations → Stock / Requirements List Material

T-F10##

Plant

1200

From the end products, dependent requirements are created that are covered by multi-level planning. 8.

Double-click a planned order to display the detail data. Why are there no pushbuttons to convert the planned order into a production order? _______________________________________________________ _______________________________________________________ a)

2009

Materials T-B10## and T-F10## are materials that are only used in repetitive manufacturing (the Repetitive Manufacturing indicator is set in the material master). The corresponding planned orders are used for production and can therefore not be converted into production orders.

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Exercise 6: Line Loading Planning in the ECC System Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Assign production quantities to production lines, taking capacities into account. The production quantities either originate in material requirements planning they are created manually and assigned to the production lines in the planning table.

Business Example One production line is available for the final assembly of your T-F10## PC and one is available for the assembly of the T-B10## motherboard. The basic dates as to quantities and periods have already been determined in MRP and production planning in the previous exercise. As the production planner, you now assign the quantities to the relevant production line.

Task: 1.

Access the ECC planning table for repetitive manufacturing from the repetitive manufacturing planning menu and assign the planned orders to the production lines, taking into account the available capacities. Access the planning table, enter plant 1200 and select a production line. First, enter the final assembly line T-L1##. Then choose Planning table. Familiarize yourself with the period-based display of quantity and capacity data in the planning table. Fields that are ready for input are shown in white, while display fields are grayed-out as usual.

2.

Double-click the quantity in the planning table section that is ready for input to display the detail data for the planned order. Which order type is assigned (F4 help)? _______________________________________________________

3.

Choose the relevant button (LKW) to activate the assignment mode for the “unassigned quantities” in the planning table section that is ready for input. Assign the unassigned quantity to the final assembly line. Continued on next page

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4.

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Double-click the quantity you have just assigned. _______________________________________________________ Which order type is now assigned (F4 help)?

5.

Look at the capacity data. Does the production line reach full capacity with the planned order in the relevant time interval or is some capacity still available for other orders in the same period? _______________________________________________________

6.

Save the line loading planning for the finished product and complete exercise 1 to 3 for assembly production (use line T-L3## and plant 1200 to access the table. Why does the quantity that was already available at the beginning (plant stock) reduce the oldest planned order in contrast to the corresponding requirement quantity? _______________________________________________________ _______________________________________________________ Save the line loading planning for the assemblies. Hint: Since there is only one production line for final assembly and one for assembly production, you could also use alternative selection (material master, MRP4 view, alternative selection indicator = 2) to plan line loading and, if required, check the results in the planning table afterwards.

7.

Optional: Create a planned order manually in the planning table. To do so, access the planning table (line T-L3##, plant 1200) and use the function keys at the bottom of the planning table (NOT with the scrollbar) to scroll to the date: “Today + 1 month ”. Enter a quantity of 300 pieces on line T-L3## and press Enter to confirm. You have manually created a planned order that can be used for production in this form. Check this in the planned order details. Do not save the order.

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Solution 6: Line Loading Planning in the ECC System Task: 1.

Access the ECC planning table for repetitive manufacturing from the repetitive manufacturing planning menu and assign the planned orders to the production lines, taking into account the available capacities. Access the planning table, enter plant 1200 and select a production line. First, enter the final assembly line T-L1##. Then choose Planning table. Familiarize yourself with the period-based display of quantity and capacity data in the planning table. Fields that are ready for input are shown in white, while display fields are grayed-out as usual. a)

SAP Menu → Logistics → Production → Repetitive Manufacturing → Planning → Planning Table → Change Mode To access the planning table, enter: Plant

1200

Selection

Production line T-L1##

Press “Planning Table” . 2.

Double-click the quantity in the planning table section that is ready for input to display the detail data for the planned order. Which order type is assigned (F4 help)? _______________________________________________________ a)

Double-click a planned order in the planning table section that is ready for input (shown in white). The planned order has order type WO warehouse order.

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3.

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Choose the relevant button (LKW) to activate the assignment mode for the “unassigned quantities” in the planning table section that is ready for input. Assign the unassigned quantity to the final assembly line. a)

Activate the assignment mode for the “unassigned” quantities in the planning table section that is ready for input by selecting the “Not yet assigned” line in the bottom “Material data” table (to select, click on the button at the start of the line) and then choosing the pushbutton with the truck icon. A symbol appears at the start of the line, signifying that you are in assignment mode for this line. Read the quantities in the “Not yet assigned” section, enter them in the field on the production line that belongs to the same period, and confirm. Deactivate assignment mode by choosing the relevant pushbutton.

4.

Double-click the quantity you have just assigned. _______________________________________________________ Which order type is now assigned (F4 help)? a)

Double-click a planned order that has been assigned to the production line in the planning table. The planned order has the order type PE (run schedule quantity).

5.

Look at the capacity data. Does the production line reach full capacity with the planned order in the relevant time interval or is some capacity still available for other orders in the same period? _______________________________________________________ a)

By dispatching a planned order on production line T-L1##, the line only reaches a comparatively low capacity load (see the planning table: Capacity data in the row for production line T-L1##). This means that you could theoretically dispatch additional quantities for the same period. Hint: The capacity data is not available on the same day as the production quantities since the quantities are determined to the day according to availability, while the capacity load of the production line is determined to the hour and minute according to the production date. You can change the display from within the planning table by choosing View → Reference Dates → Production Dates.

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6.

Save the line loading planning for the finished product and complete exercise 1 to 3 for assembly production (use line T-L3## and plant 1200 to access the table. Why does the quantity that was already available at the beginning (plant stock) reduce the oldest planned order in contrast to the corresponding requirement quantity? _______________________________________________________ _______________________________________________________ Save the line loading planning for the assemblies. Hint: Since there is only one production line for final assembly and one for assembly production, you could also use alternative selection (material master, MRP4 view, alternative selection indicator = 2) to plan line loading and, if required, check the results in the planning table afterwards. a)

In make-to-stock production, plant stock is included in the net requirements calculation. Save the line loading planning for finished product T-F10##. SAP Menu → Logistics → Production → Repetitive Manufacturing → Planning → Planning Table → Change Mode To access the planning table, enter: Plant

1200

Selection

Production line T-L3##

Press “Planning Table” . Switch to assignment mode for the “unassigned” quantities in the planning table section that is ready for input by selecting the “Not yet assigned” line and then choosing the pushbutton with the truck icon. Read the quantity in the “Not yet assigned” section, enter it in the field on the production line that belongs to the same period, and confirm. Deactivate assignment mode and save your changes. The T-B10## assembly (which does not belong to any sales order) is in stock, which means that the existing stock can be used for production planning.

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7.

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Optional: Create a planned order manually in the planning table. To do so, access the planning table (line T-L3##, plant 1200) and use the function keys at the bottom of the planning table (NOT with the scrollbar) to scroll to the date: “Today + 1 month ”. Enter a quantity of 300 pieces on line T-L3## and press Enter to confirm. You have manually created a planned order that can be used for production in this form. Check this in the planned order details. Do not save the order. a)

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Exercise 7: Material Staging and Backflush Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Use the pull list to stage components on your production line • Carry out quantity-based and period-based backflushing in repetitive manufacturing

Business Example For assembly production of motherboard T-B10##, you want to check for missing components in the production storage location PL03 and use stock transfer measures to stage missing components for a certain production period. After a production section has been completed, the quantity produced is backflushed in the system. Both tasks are within the supervisor’s or production scheduler’s area of responsibility. You will assume these roles in the following exercise.

Task 1: You will use the pull list to execute the stock transfer from storage to the production line. Execute component staging at assembly production line T-L3##. 1.

Access the pull list from the Repetitive Manufacturing menu. Staging is performed for line T-L3## in plant 1200 for all requirements that are received until Tuesday of the week after next. In this example, material staging is performed at storage location level (note that the pull list also supports additional staging types: using the Warehouse Management System or event-driven KANBAN) by stock transfer from the central warehouse 0001 to the production storage location PL03. Some steps in the pull list can be carried out automatically. Make the following “global settings”. Dialog Control tab: Field name

Value

Create replenishment proposals

Automatic

Batch/stock determination

Automatic

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Field name

Value

Stage replenishment elements

In dialog

Post replenishment elements

In dialog

Print replenishment elements

In dialog

Execute the report and note the status bar. 2.

Go to the pull list. Interpret the results of the automatic steps. For which materials are there shortfall quantities until Tuesday of the week after next due to the planned requirements? How large are these quantities?

3.

At which storage location are there shortfall quantities?

4.

At which storage location has the system found a replenishment quantity?

5.

Can the complete shortfall quantity be covered from here?

6.

You accept the system proposal. Choose “Stage” to trigger material staging for the relevant components from warehouse 0001 to production storage location PL03.

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Caution: Material staging (using direct stock transfer in this case) is not carried out until you save the pull list. If you need a printout of the list for the physical stock transfer, we recommend printing it before you save (Pull list – Print). Save the list. 8.

Check the stock transfer posting in the message log for the pull list (in a separate transaction).

Task 2: After completion of a production unit (predefined in terms of both time and quantity) and in which you produced 90 motherboards on line T-L3##, you need to backflush the quantity produced in the system. 1.

First, open a second session of the planning table for repetitive manufacturing (which you access by selecting production line T-L3##, plant 1200).

2.

In the first session, backflush 90 pieces of the motherboard material T-B10## produced on line T-L3## in plant 1200. To do so, enter the data in the backflush transaction, which you can access from the Backflush menu for repetitive manufacturing. Then choose “Post with correction”.

3.

Look at the next screen and explain which components of assembly T-B10## were backflushed on the line but do not exit this display: _________________________________________________________ _________________________________________________________ _________________________________________________________

4.

Due to a technical defect in a machine, you needed 3.5 hours to produce 90 pieces instead of 3 hours as specified in the production rate in the routing (30 pieces per hour). To correct this, choose “Actual activities”. On the next screen, select the only line proposed and confirm. In the next window, select the “ProdTime” field under “Activities” and overwrite the planned value under “Backflush quantity” with the actual value (3.5 hours). Press Enter to confirm and then choose Save.

5.

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Go to the second session (planning table) and look at the quantities on the line while pressing F5 (refresh). How have the planned quantities changed?

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Solution 7: Material Staging and Backflush Task 1: You will use the pull list to execute the stock transfer from storage to the production line. Execute component staging at assembly production line T-L3##. 1.

Access the pull list from the Repetitive Manufacturing menu. Staging is performed for line T-L3## in plant 1200 for all requirements that are received until Tuesday of the week after next. In this example, material staging is performed at storage location level (note that the pull list also supports additional staging types: using the Warehouse Management System or event-driven KANBAN) by stock transfer from the central warehouse 0001 to the production storage location PL03. Some steps in the pull list can be carried out automatically. Make the following “global settings”. Dialog Control tab: Field name

Value

Create replenishment proposals

Automatic

Batch/stock determination

Automatic

Stage replenishment elements

In dialog

Post replenishment elements

In dialog

Print replenishment elements

In dialog

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Execute the report and note the status bar. a)

SAP menu → Logistics → Production → Repetitive Manufacturing → Material Staging → Pull List - Trigger Replenishment Staging type

Storage location level

Plant

1200

Selection period

Tuesday of the week after next

On the “Planned orders” tab, select: Production line

T-L3##

Choose “Global settings”. On the “Dialog control” tab page, select: Field name

Value

Create replenishment proposals

Automatic

Batch/stock determination

Automatic

Stage replenishment elements

In dialog

Post replenishment elements

In dialog

Print replenishment elements

In dialog

Confirm your entries and execute the report. 2.

Go to the pull list. Interpret the results of the automatic steps. For which materials are there shortfall quantities until Tuesday of the week after next due to the planned requirements? How large are these quantities? Answer: Due to the planned requirements, there are shortfall quantities for material T-T6## until Tuesday of the week after next. The system automatically created a replenishment proposal and determined stock for component T-T6## in storage location 0001. The pull list shows the size of the shortfall quantity.

3.

At which storage location are there shortfall quantities? Answer: There are shortfall quantities at production storage location PL03, where the components for assembly production are to be staged.

4.

At which storage location has the system found a replenishment quantity? Answer: The replenishment quantity was found in central warehouse 0001. Continued on next page

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5.

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Can the complete shortfall quantity be covered from here? Answer: Yes, the staging quantity is equal to the shortfall quantity.

6.

You accept the system proposal. Choose “Stage” to trigger material staging for the relevant components from warehouse 0001 to production storage location PL03. a)

–

7. Caution: Material staging (using direct stock transfer in this case) is not carried out until you save the pull list. If you need a printout of the list for the physical stock transfer, we recommend printing it before you save (Pull list – Print). Save the list. a) 8.

–

Check the stock transfer posting in the message log for the pull list (in a separate transaction). a)

SAP menu → Logistics → Production → Repetitive Manufacturing → Material Staging → Log Access the log from the Material Staging menu, enter today’s date as the “To” date, and choose “Execute”. The stock transfer was successfully posted in the system.

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Task 2: After completion of a production unit (predefined in terms of both time and quantity) and in which you produced 90 motherboards on line T-L3##, you need to backflush the quantity produced in the system. 1.

First, open a second session of the planning table for repetitive manufacturing (which you access by selecting production line T-L3##, plant 1200). a)

SAP menu → Logistics → Production → Repetitive Manufacturing → Data Entry → Repetitive Manufacturing Confirmation Select System – Create Session to open a new session and use the following path: SAP Menu → Logistics → Production → Repetitive Manufacturing → Planning → Planning Table → Change Mode To access the planning table, enter: Plant

1200

Selection

Production line T-L3##

Press “Planning Table”. 2.

In the first session, backflush 90 pieces of the motherboard material T-B10## produced on line T-L3## in plant 1200. To do so, enter the data in the backflush transaction, which you can access from the Backflush menu for repetitive manufacturing. Then choose “Post with correction”. a)

Enter the following data on screen of the Backflush transaction screen: Backflush type

Assembly backflush

Backflush quantity

90 pieces

Material

T-B10##

Plant

1200

Prod. version

0001*)

*) The production version contains the production on line T-L3##. Choose “Post with correction”. 3.

Look at the next screen and explain which components of assembly T-B10## were backflushed on the line but do not exit this display: _________________________________________________________ _________________________________________________________ Continued on next page

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_________________________________________________________ a)

4.

The current BOM was exploded during the backflush. The system determined the materials to be backflushed in the BOM explosion. The all or nothing principle applies, which means that all four materials displayed are backflushed.

Due to a technical defect in a machine, you needed 3.5 hours to produce 90 pieces instead of 3 hours as specified in the production rate in the routing (30 pieces per hour). To correct this, choose “Actual activities”. On the next screen, select the only line proposed and confirm. In the next window, select the “ProdTime” field under “Activities” and overwrite the planned value under “Backflush quantity” with the actual value (3.5 hours). Press Enter to confirm and then choose Save. a)

5.

–

Go to the second session (planning table) and look at the quantities on the line while pressing F5 (refresh). How have the planned quantities changed? a)

Go to the second session (planning table) and choose F5 (refresh the planning table). The oldest planned order quantity or quantities are reduced according to the backflush quantity. Explanation: For demonstration purposes, the backflush was made with a date (today) that is before the actual production dates. The backflush quantity is therefore interpreted as “over-production” that reduces subsequently planned orders accordingly (oldest planned orders first).

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Lesson: Functions and Process Steps in Repetitive Manufacturing

Lesson Summary You should now be able to: • Describe the main steps in repetitive manufacturing • Evaluate the main functions within repetitive manufacturing

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Unit Summary You should now be able to: • Explain the characteristics of period-based repetitive manufacturing • Describe the main steps in repetitive manufacturing • Evaluate the main functions within repetitive manufacturing

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Test Your Knowledge

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Test Your Knowledge 1.

Name some basic functions of repetitive manufacturing.

2.

List the basic processing steps in repetitive manufacturing.

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Answers 1.

Name some basic functions of repetitive manufacturing. Answer: • • • • • • • • •

2.

Scheduling Calculation and monitoring of capacity requirements Costing Availability checks Printing of production list and operational method sheet Material staging (without reservations) Goods issue: Standard backflush Goods receipt: Closely linked to final confirmation (quantities and activities) Period-end closing

List the basic processing steps in repetitive manufacturing. Answer: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

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Requirements Line loading planning and capacity monitoring Availability check Printing the operational method sheet Printing the production list Material staging Production execution WIP calculation (optional in the case of reporting point confirmation) Final confirmation and stock receipt with component backflushing Settlement using the product cost collector

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Unit 4 Kanban

143

For demonstrations and instructor notes, see the instructor guide on the SAP Corporate Portal.

Unit Overview In this unit, you will learn about the KANBAN functions.

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

Explain the characteristics of the KANBAN principle Describe the main steps of the KANBAN procedure Assess the main functions of the KANBAN principle

Unit Contents Lesson: Features of the KANBAN Procedure...............................150 Lesson: The KANBAN Procedure ............................................156

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Features of the KANBAN Procedure Lesson Duration: 15 Minutes

Lesson Overview This lesson outlines the principle of the KANBAN procedure.

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

Explain the characteristics of the KANBAN principle

For demonstrations and instructor notes, see the instructor guide on the SAP Corporate Portal.

Business Example A distinctive feature of your company is a relatively constant consumption of materials. For this reason, you want to process the material flow in your company’s production to the work centers using an event-driven approach. You first use the KANBAN functions to familiarize yourself with organizing replenishment using stock transfers, external procurement, and in-house production.

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Application Areas

Figure 53: Application Areas

The application areas are not restricted to certain industries. The above graphic merely contains a selection. The KANBAN principle can be used together with all other production types.

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KANBAN Principle

Figure 54: KANBAN Principle

In KANBAN, material flow is organized using containers that are situated at the work centers in the production location. Each contains the quantity of material that work center personnel need for a certain period of time. As soon as a container is emptied by the demand source, replenishment is initiated in KANBAN. The supply source for the required material can be another production unit, an external vendor, or a warehouse. The demand source can use material from other containers until the actual container is returned full. The aim is that production itself controls the replenishment process and the manual posting effort for personnel is kept to a minimum. This self-management process and the fact that replenishment elements are created close to the time they are actually consumed means that stocks are reduced and lead times are shortened (replenishment is only triggered when a material is actually required and not before). KANBAN in summary: Material is staged where it is used, and is always available in small material buffers. This means that material staging does not need to be planned. Instead, material that is consumed is replenished immediately using KANBAN. By using KANBAN with the SAP ECC system, you can automate the transfer of replenishment data. For example, scanning the barcode on a KANBAN card is sufficient to transfer the data required for procurement and to post the goods receipt when the material is received.

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KANBAN: Characteristics

Figure 55: KANBAN: Characteristics

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Facilitated Discussion To be able to describe the KANBAN principle.

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: Features of the KANBAN Procedure

Lesson Summary You should now be able to: • Explain the characteristics of the KANBAN principle

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Lesson: 148

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The KANBAN Procedure Lesson Duration: 20 Minutes

Lesson Overview This lesson outlines the prerequisites for the KANBAN procedure and how it is implemented.

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

Describe the main steps of the KANBAN procedure Assess the main functions of the KANBAN principle

For demonstrations and instructor notes, see the instructor guide in the SAP Corporate Portal.

Business Example You decide to organize replenishment using stock transfers, external procurement, and in-house production with the SAP SCM KANBAN functions.

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Lesson: The KANBAN Procedure

Using KANBAN in Production

Figure 56: Using KANBAN in Production

In the general production process, the KANBAN principle is used within material staging.

Master Data

Figure 57: Master Data: Supply Area

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The structure and organization of production are important criteria when introducing KANBAN. With KANBAN, material is staged in specific areas (known as supply areas) directly in production. A supply area can be used by one or more work centers. The supply areas act as a buffer for the required materials (for example, on shelves or in marked-out areas on the floor). The supply areas established for the shop floor are defined in the ECC System in the KANBAN menu. In the definition, the supply area is assigned the following objects: The supply area is a data object used to organize material flow for KANBAN. It is not an inventory management object. Therefore, storage locations must be assigned to the supply areas. Inventory management (which is relevant, for example, for posting goods receipts) takes place at the storage location to which the supply area is assigned. Another significant organizational prerequisite is that you create a person who is responsible for each supply area. The person assigned to a supply area is responsible as the demand source for processing material and for monitoring stocks in the supply area. The person responsible entered in the control cycle for in-house production is responsible as the supply source for replenishment, that is, for material provision and, if necessary, for delivery to the demand source. The person responsible is assigned as an MRP controller to the supply area in Customizing for MRP. Unloading point: In external procurement, the supplier often delivers the material directly to a certain unloading point rather than to the supply area in production. The KANBANS are then transported from this unloading point to the supply area. The unloading point defines where the supplier has to deliver the material (for example, gate 1). It is printed on the KANBAN card or is transferred to the summarized JIT call. Delivery address: You can maintain an address in the supply area. When you create a control cycle, this address is transferred to the delivery address of the control cycle.

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Figure 58: Master Data: KANBAN Control Cycle

To control the relationship between supply and demand source, you define a control cycle. The control cycle defines: • •

•

• • •

• •

The demand source (supply area) The replenishment strategy (for example, replenishment using a purchase order for external procurement, using run schedule quantities for in-house production or using stock transfer reservations for stock transfer) The supply source (supplier or issuing plant for external procurement, the person responsible for in-house production, the storage location for stock transfer) The number of containers (KANBANs) circulating between the demand and the supply source The quantity for each container The delivery address (when you use the function, the plant address is automatically maintained). Here, you can also enter detailed information required for the supply area. You can print this data on a KANBAN card, for example. Print parameters for printing the KANBAN card. The pallet position: More precise specification of the material’s position (for example, a specific shelf section) in the supply area. The pallet position can also be printed on the KANBAN card. Parameters for the automatic KANBAN calculation.

You can also delete or lock KANBANs in the control cycle. You lock a KANBAN, for example, if it is not going to be used for a certain period because consumption has reduced within the control cycle.

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Figure 59: Production Supply Using Control Cycles

When you use the KANBAN procedure, warehouses or vendors are linked to the supply areas that are assigned to the relevant producion storage locations using control cycles. Since the link to material staging can also take place using in-house production within KANBAN, pre-assembly and final assembly can, for example, be linked using KANBAN.

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KANBAN Status

Figure 60: Setting the KANBAN to EMPTY = Triggering Replenishment

The progress of production in KANBAN is controlled by setting the KANBAN to the appropriate status. Usually, only the Empty and Full statuses are used. If the demand source sets the status to empty, the system creates a replenishment element, instructing the material supply source to deliver. Emptying a KANBAN does not result in a goods issue posting. In KANBAN, goods issues are typically backflushed when an order is confirmed (or when a goods issue is posted manually for an order). You can set the status to Empty by scanning a bar code on the KANBAN card. To do this, you scan the bar code using a standard bar code scanner in the Kanban Signal → Bar Code transaction. You can also set the status to EMTPY using the manual kanban signal transaction or the KANBAN board.

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Figure 61: Setting KANBAN to Full = Posting Goods Receipt

If the demand source sets the status to Full, the system automatically posts the goods receipt for the material with reference to the procurement element. You can set the status to Full by scanning a bar code on the KANBAN card. To do this, you scan the bar code using a standard bar code scanner in the Kanban Signal → Bar Code transaction. You can also set the status to Full using manual kanban signal transaction or in the KANBAN board.

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Plan-Controlled Production versus KANBAN

Figure 62: Plan-Controlled Production versus KANBAN

Advantages of KANBAN: • • • •

2009

KANBAN is a simple form of production control: To a large extent, production itself controls replenishment. Manual posting effort is minimized. The material is available directly on the shop floor. This saves the organizational effort required to stage the material. The production quantities correspond to actual requirements. This automated process and the fact that replenishment elements are created close to the time they are actually consumed means that stocks are reduced and lead times are shortened (replenishment is only triggered when a material is actually required and not before).

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Facilitated Discussion Understand the prerequisites and the KANBAN procedure

Discussion Questions Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions. Name key characteristics of the KANBAN procedure and discuss possible areas of operation.

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Lesson: The KANBAN Procedure

Lesson Summary You should now be able to: • Describe the main steps of the KANBAN procedure • Assess the main functions of the KANBAN principle

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Unit Summary

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Unit Summary You should now be able to: • Explain the characteristics of the KANBAN principle • Describe the main steps of the KANBAN procedure • Assess the main functions of the KANBAN principle

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Test Your Knowledge

157

Test Your Knowledge 1.

What are the objectives of the KANBAN procedure?

2.

Which objects are used to organize the material flow in the KANBAN procedure? Choose the correct answer(s).

□ □ □ □ □ □

A B C D E F

Material buffers Warehouses Containers Replenishment Vendors Cards

3.

How is replenishment initiated in the KANBAN procedure?

4.

The supply source for the required material can be , an , or a

.

Fill in the blanks to complete the sentence.

5.

Name the basic master data of KANBAN.

6.

Setting the KANBAN to

= Triggering Replenishment

Fill in the blanks to complete the sentence.

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Setting Fill in the blanks to complete the sentence.

168

8.

When is the goods issue typically posted in KANBAN?

9.

When is the goods receipt typically posted in KANBAN?

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Test Your Knowledge

159

Answers 1.

What are the objectives of the KANBAN procedure? Answer: The following objectives can be achieved in many cases by controlling the production process in production itself and by reducing the manual posting effort required: • •

2.

Shortening the lead times Reducing stock

Which objects are used to organize the material flow in the KANBAN procedure? Answer: C, F In KANBAN, material flow is organized using containers that are situated at the work centers in the production location. Each contains the quantity of material that work center personnel need for a certain period of time. Scanning the barcode on a KANBAN card is sufficient to transmit all the data required for procurement. This card describes which material is to be delivered where and the quantity to be delivered.

3.

How is replenishment initiated in the KANBAN procedure? Answer: In the KANBAN procedure, replenishment is initiated when the demand source sets the container in the system to “empty”.

4.

The supply source for the required material can be another production unit, an external vendor, or a warehouse. Answer: another production unit, external vendor, warehouse

5.

Name the basic master data of KANBAN. Answer: • •

6.

Supply areas Control cycles

Setting the KANBAN to EMPTY = Triggering Replenishment Answer: EMPTY

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Test Your Knowledge

7.

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Setting KANBAN to Full= Posting Goods Receipt Answer: KANBAN to Full= Posting Goods Receipt

8.

When is the goods issue typically posted in KANBAN? Answer: In KANBAN, goods issues are typically backflushed when an order is confirmed (or when a goods issue is posted manually for an order). Emptying a KANBAN does not result in a goods issue posting.

9.

When is the goods receipt typically posted in KANBAN? Answer: If the demand source sets the status to Full, the system automatically posts the goods receipt for the material with reference to the procurement element.

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2009

Unit 5 Capacity Requirements Planning (ERP)

161

Display the slides for the unit and explain the essential elements of capacity requirements planning.

Unit Overview This unit explains the main elements of capacity requirements planning.

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

Review the basic functions of capacity planning Use the options of capacity evaluation. Explain the development of capacity requirements Explain the reduction of capacity requirements Use the leveling function of the tabular capacity planning table. Maintain available capacity. Maintain and assign shift sequences. Use the detailed scheduling planning board. Use planning strategies.

Unit Contents Lesson: Capacity Planning Environment ....................................173 Lesson: Capacity Evaluation ..................................................180 Exercise 8: Standard Overview...........................................193 Lesson: Capacity Leveling in Table Form ...................................198 Exercise 9: Tabular Capacity Planning Table ...........................209 Lesson: Available Capacity....................................................214 Lesson: Capacity Leveling in Graphical Form ..............................220

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Exercise 10: Planning Strategies.........................................229

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Lesson: 162

Lesson: Capacity Planning Environment

Capacity Planning Environment Lesson Duration: 60 Minutes

Lesson Overview This lesson provides an overview of the capacity planning environment, the components and display types.

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

Review the basic functions of capacity planning

Only provide a rough overview of supply chain planning here.

Business Example Your company is a manufacturing company, and you want to get an overview of SAP capacity planning. Therefore, you want to find out about the capacity planning environment. Before you show the next slide, you should develop this slide with the participants on the board or flip chart. Ask questions such as: • • •

What are the two main functions of capacity planning? What data does the system calculate for capacity planning? Which master data do you think is required for capacity evaluation and capacity leveling? After you have done this, compare this slide with the slide in the training system. Explain that this slide is used throughout the course to clarify which areas of capacity planning are currently being covered.

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Figure 63: Capacity Planning Environment

Master data, planned orders and production orders provide data that can be used to represent available capacities and capacity requirements. In the SAP ECC system, master data consists of material masters, routings and work centers. Available capacity indicates which activities a capacity can perform per workday. Capacity requirement indicates which activity the individual orders require for a capacity at a certain point in time. Scheduling is used to determine the times of the capacity requirements. In the capacity evaluations, these requirements can be compared with the available capacities. In capacity leveling, overloads and under-utilization can be leveled. This allows users to alternate to appropriate work centers or use the sort criteria to plan optimal loading and commitments.

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Explain the following points: 1. 2. 3.

The following master data is important for capacity planning: Material masters, bill of materials, routings and work centers with capacities. The two main functions of capacity planning are capacity evaluation and capacity leveling. The two most important factors that are compared in this context are available capacity and capacity requirement. •

•

Ensure that the capacity is expressed in time units. Refer to the fact that the source of the capacity data for the work center is assigned to the capacity category. The sources for the capacity requirement include planned orders and production orders.

Figure 64: Capacity Planning/Elements

Available capacity represents the capacity available for production at a work center or resource. The times for the capacity requirements are determined by scheduling the sequence of operations. To calculate the capacity requirement, the system uses formulas containing the dates and quantities for production requirements. The capacity evaluation gives you an overview of the load and the production requirements.

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Capacity leveling allows you to achieve optimal planning and an optimal load. Capacity reduction occurs when operations are confirmed or order quantities reduced or deleted. Explain the following points: 1.

2. 3. 4.

The available capacity arises from the capacity categories at the work center or capacities such as reference or pooled capacities, for example, which are assigned to work centers. Scheduling involves lead time scheduling. In detailed planning, the capacity requirement is calculated using standard values in the routing and formulas in the work center. The capacity load reduction takes place with confirmations and by setting a particular order status.

Figure 65: Display Types

Capacity planning uses several display types. It uses evaluation lists, block diagrams, bar charts, line graphs and Gantt charts. You can also carry out simulations with the tabular capacity planning table or the graphical capacity planning tables.

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Lesson: Capacity Planning Environment

Explain the different display types for capacity evaluation and capacity leveling. Explain that there is both a tabular and graphical capacity planning table for capacity leveling.

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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: • Review the basic functions of capacity planning

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Capacity Evaluation Lesson Duration: 45 Minutes

Lesson Overview This lesson deals with the options for analysis of the capacity load.

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

Use the options of capacity evaluation. Explain the development of capacity requirements Explain the reduction of capacity requirements

Explain the different transaction calls for capacity evaluation. By selecting one of the entries in the Evaluation → Work Center View menu, you access the capacity evaluation using overall profiles with determined default settings. You can call up other initial screens using Set/Get parameters in the user master record.

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Load

SAPX911

CY1

Sales Orders

SAPX912

CY2

Pool

SAPX913

CY3

Backlog

SAPX914

CY4

Overload

SAPX915

CY5

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Lesson: Capacity Evaluation

In the Variable menu (Evaluation → Variable), the user can select an overall profile from a list of all overall profiles. •

Load: All remaining requirements for the next 2 months in a weekly period split in the standard overview

•

Orders: Only orders for the next 2 months in a weekly period split in the detailed capacity list

•

Pool: Only released orders for the next 2 weeks in a daily period split in the detailed capacity list

•

Backlog: Orders in the backlog with the date yesterday

•

Overload: Work centers and capacities with overload in the next 2 months

Business Example In your company, numerous evaluations are required for the capacity situation of work centers and the personnel. You use the options of the ECC system for evaluations like this.

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Figure 66: Procedure in Capacity Evaluation

The following options exist for the evaluation of the capacity load: • • • •

Simple evaluation (capacity requirements planning menu) Advanced evaluation (capacity requirements planning menu) Orderinformation system (PP-SFC menu) ShopFloor Information System (capacity requirements planning, PP-SFC, LIS, and so on)

Capacity evaluations are structured based on two different initial menus. •

•

The Variable access provides the user with variable access with user-defined selection of the profile delivered for capacity evaluations (standard) or created by the user (user-specific). The Work center view access creates evaluations for loads, orders, pool, backlog or overload with profiles specifically defined in the standard system.

When accessing the capacity evaluation, the Customizing settings are defined from the overall profile. This overall profile can be a default profile provided by SAP or a user-specific profile. In the evaluation, you can use the Settings menu option to change the display. You can use the Selection menu option to supplement or restrict the capacity evaluation with additional criteria.

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Figure 67: Overall Profile

The overall profile includes four subprofiles with the following meanings: The selection profile determines which sets are accessed to generate the various selection screens, and for which period the capacity requirements are read from the database. •

The order set, the capacity category set, and the work center set are used for additional selection criteria.

The list profile specifies the layout of the detailed capacity list and the variable overview, and determines which list is automatically displayed. The graphics profile contains settings for the layout of the various graphics: • • •

Determining the earliest/latest dates of operations Sort sequence such as date, material number, order number Displaying columns, bars or lines

In the options profile, the default parameters are specified for the type of display, the display period, distribution and branching in display or change mode. An overall profile can be accessed with the user parameters CY1 - CY7 individually for every user.

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Figure 68: Standard Overview

The standard overview periodically compares the available capacity with the capacity requirements for the selected work centers for each capacity category. The loads and remaining available capacity are also listed. From the standard overview, you can generate graphics, print lists, maintain work centers and capacities, and you can use the detailed capacity list to process orders. The standard overview can be restricted using minimum and maximum load percentages. You can predefine these in the options profile.

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Figure 69: Selection and Display Parameters

The selection and display parameters can be predefined in profiles, but can be changed in the menu General Settings. You can only maintain the read time segment in Customizing. Standard Overview Describe the standard overview and the general settings. From the standard overview, you can change to both of the other evaluations and branch to a number of additional functions. Under Settings → Evaluations → Standard overview, you can enter the minimum or maximum load to be displayed. As an example, only display the minimum or maximum load in the standard overview: Under approx. 10%: Unimportant, over 120%: is taken over by someone else.

Overall Profile Give the course participants a general overview of how to call up the capacity evaluation. To work with capacity evaluation, you require an overall profile with four subprofiles.

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By calling this overall profile, you can produce the required combinations of subprofiles for the result you want.

Selection and Display Parameters Discuss the settings that can be preconfigured using the options profile. Explain that period splits can be changed on an ongoing basis. One of the settings refers to the cumulation of the available capacity. The system can summarize available capacities from lower hierarchy levels. For example: Using the cumulation of the available capacity of a work center group: A department comprises multiple work centers and as head of department you want an overview of the entire available capacity.

Demonstration: Standard Overview Show the standard overview and the general settings. 1. 2. 3. 4. 5.

Evaluation → Work Center View → Load Use work center R-V99, plant 1000 Display the standard overview Select a period with capacity requirements and select Cap. details/period. Choose Back. Display the settings. Settings → General a. Period display and evaluation period are displayed b. Cumulate over periods, unit of measure c. Refer to the hierarchy data (but do not display it, since it is covered in another unit) c. Refer to the distribution data (but do not display it, since it is covered in another unit) e. Available capacity: Capacity version

6.

7.

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Show how you can select several work centers using the Planning → Selection → Work center menu option and the detailed selection or hierarchy functions. Show the graphic for the standard overview.

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Figure 70: Detailed Capacity List and its Functions

In the detailed capacity list, the orders and their operations are listed by period depending on which work center is selected. They may be sorted, for example, by order number, date, and priority. From this list, you can make changes to the work center, capacity, and order. Users can call up additional information about the material and the stock/requirements situation. Users can predefine the display using the list profile and change it using the settings menu.

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Figure 71: Capacity Planning Environment

From the Detailed Capacity screen, you can use the Environment menu option to navigate to other sections of PPS, partly for making changes and partly for display only. In the options profile in Customizing you can specify that the system is to branch to orders, the work center and the capacity in change mode or in display mode. You can also branch to other screens by double-clicking on the fields for the order, the work center or the capacity.

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Figure 72: Capacity Requirement Calculation

To determine capacity requirements, capacity requirements records are written for every operation and every capacity. Every capacity requirements record contains the dates and the requirements for setup, processing and tear down.

Figure 73: Setting up a Formula for Volume Requirements

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The parameters are distinguished by their origin. You can define the following origins for a parameter in Customizing: •

• • • • •

•

General operation value: The parameter is assigned a field directly from the general operation data. The value of this field goes into the formula. Typical fields are lot size, base quantity, number of splits and the amount of capacity. Work center constant: The parameter is assigned a fixed value in the work center and this value goes into the formula. Standard value: A standard value is assigned to the parameter that goes into the formula. The assignment is by means of the standard value key. User field of operation: The parameter is assigned a user-specific data field for the operation. Value from PRT assignment: This may involve both the quantity and the usage value of the PRT. PRT constant: The parameter is assigned a fixed value in the master record of the production resource/tool. Can only be used for formulas within the PRT administration. General formula constant: This parameter can be assigned a value that is then copied to the application.

Figure 74: Capacity load reduction

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Lesson: Capacity Evaluation

Capacity requirements are reduced or completely deleted with the following actions: •

With order confirmation during

•

– Confirmation of quantities – Confirmation of forecast standard values – Confirmation in another work center Setting the status – – –

SPER Lock TABG Technical completion and LÖVM Deletion indicator

The method of capacity reduction must be set using an indicator on the capacity header screen of the work center for every capacity requirement element (as of Release 4.7). See the following slide.

Figure 75:

Up to Release 4.6C, there was only one option for reducing capacities: Quantity-based reduction. As of Release ERP, the four options mentioned above are available. For control purposes, a new ( Control capacity reduction indicator) is provided in the work center “ on the Capacities” tab for each of the three fixed capacity segements (setup, processing tear down). As a result, you can implement the following variants:

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Proportional to confirmed quantities: In proportion to the confirmed quantity: Remaining capacities are calculated on the basis of the remaining quantity using either the standard values for each activity type or a forecast standard value based on the confirmed values (forecast). The work center formulas are used for this. The default value for setups is set with the first partial confirmation to zero. All other remaining capacities can only be set to zero by setting the remaining quantity to zero or the forecast value to zero. Proportional to confirmed activity: In this type of requirement reduction, it is not the confirmed quantity but the reported activity that determines the remaining requirements. To do this, the system first determines the record type group (capacity segment) that is assigned to the activity type in the work center (on the Costingtab). The system then uses the ratio of the actual activity to the planned activity to determine the remaining capacity requirement and assigns it to the capacity segment. Complete on partial or final confirmation: The status of the confimation is evaluated and the complete, still open capacity requirement is completely reduced. For orders, that are planned in SAP APO, the indicator has no effect on the capacity reduction in APO.

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Lesson: Capacity Evaluation

Exercise 8: Standard Overview Exercise Duration: 15 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Use the standard overview in the capacity evaluation • Change the displays

Business Example As a capacity planner in your company, you must compare the capacity requirements with the available capacity in an overview. To do this, choose the standard overview in the capacity evaluation and switch to "Cumulate over periods" if necessary.

Task 1: For capacity planning, create planned independent requirements for the R-F1## material. Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Create 1.

On the initial screen, enter the material R-F1## plant 1000, and planning period W for the week format. Adopt the proposed planning period. Select Enter to confirm the entries.

2.

In the planning table, enter a quantity of 50 in the third week, a quantity of 100 in the fourth week, and 200 pieces in the fifth week.

3.

On the "Sched. lines" tab page, enter D for the daily format in the Spl column. Save the determined planned quantities.

Task 2: Now execute a single–level planning run for your material. Logistics → Production → MRP → Planning → Single-Item, Single-Level 1.

Enter the material number on the initial screen. Select the indicator 2 (Lead time scheduling and capacity planning) in the "Scheduling" field. Choose Enter twice to confirm your entries. Use the yellow arrow to exit the planning transaction.

Continued on next page

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Execute a collective conversion of the planned orders for your R-F1## material. Logistics → Production → Shop Floor Control → Order → Create → Collective Conversion of Planned Orders Choose Select all and Convert.

Task 3: Take a look at the capacity loads for your work centers in the standard overview using your capacity planner group R##. Logistics → Production → Capacity Planning → Evaluation → Work Center View → Load 1.

In which evaluation period were the capacity requirements read? Settings → General The next 60 days starting from today

2.

Change the settings in such a way that only those periods with a load greater than 80% are displayed. Settings → Evaluations → Standard overview

Task 4: Now call up the standard overview for the work center R-E##. 1.

Change the display of the standard overview by displaying a period for 3 days. Settings → General and radio button Day, Duration 3

2.

Switch again to the period display for a week and set the indicator for "Cumulate over periods". Analyze the new standard overview over the entire evaluation period. Settings → General Cumulate over periods Take a look at the pegged requirement in the first period with capacity requirements. What kind of pegged requirement is there? Select the first period and choose Cap. details/period.

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Solution 8: Standard Overview Task 1: For capacity planning, create planned independent requirements for the R-F1## material. Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Create 1.

On the initial screen, enter the material R-F1## plant 1000, and planning period W for the week format. Adopt the proposed planning period. Select Enter to confirm the entries. a)

2.

In the planning table, enter a quantity of 50 in the third week, a quantity of 100 in the fourth week, and 200 pieces in the fifth week. a)

3.

On the "Sched. lines" tab page, enter D for the daily format in the Spl column. Save the determined planned quantities. a)

Task 2: Now execute a single–level planning run for your material. Logistics → Production → MRP → Planning → Single-Item, Single-Level 1.

Enter the material number on the initial screen. Select the indicator 2 (Lead time scheduling and capacity planning) in the "Scheduling" field. Choose Enter twice to confirm your entries. Use the yellow arrow to exit the planning transaction. a)

2.

Execute a collective conversion of the planned orders for your R-F1## material. Logistics → Production → Shop Floor Control → Order → Create → Collective Conversion of Planned Orders Choose Select all and Convert. a)

Continued on next page

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Task 3: Take a look at the capacity loads for your work centers in the standard overview using your capacity planner group R##. Logistics → Production → Capacity Planning → Evaluation → Work Center View → Load 1.

In which evaluation period were the capacity requirements read? Settings → General The next 60 days starting from today a)

2.

Change the settings in such a way that only those periods with a load greater than 80% are displayed. Settings → Evaluations → Standard overview a)

Task 4: Now call up the standard overview for the work center R-E##. 1.

Change the display of the standard overview by displaying a period for 3 days. Settings → General and radio button Day, Duration 3 a)

2.

Switch again to the period display for a week and set the indicator for "Cumulate over periods". Analyze the new standard overview over the entire evaluation period. Settings → General Cumulate over periods Take a look at the pegged requirement in the first period with capacity requirements. What kind of pegged requirement is there? Select the first period and choose Cap. details/period. a)

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Lesson: Capacity Evaluation

Lesson Summary You should now be able to: • Use the options of capacity evaluation. • Explain the development of capacity requirements • Explain the reduction of capacity requirements

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Capacity Leveling in Table Form Lesson Duration: 120 Minutes

Lesson Overview This lesson describes the use of and application options for the tabular capacity planning table.

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

Use the leveling function of the tabular capacity planning table.

Ask the course participants to name all possible solutions they can think of to solve a capacity problem. Summarize these on a flip chart. Show the next slide to ensure that the participants have found all the options.

Business Example In your production process, you want to level the capacity loads on the resources. To do this, you use the capacity leveling functions to compare the capacity requirements with the available capacity. Capacity leveling is first carried out with the tabular capacity planning table and then saved after the results are checked.

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Lesson: Capacity Leveling in Table Form

Figure 76: Capacity Leveling Measures

The following methods are available for capacity leveling: •

• • •

Adjust the available capacity by increasing the standard available capacity for the relevant capacity category or increase the available capacity by inserting an interval of available capacity. Determine an alternative work center with remaining available capacity, for example, by calling up the planning table using a work center hierarchy. Find a period with sufficient remaining available capacity by dispatching using finite scheduling or manually on the planning table. Form optimal sequences to reduce setup times.

You can only reduce/split the lot, or specify that operations are to be assigned externally, in the production order.

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Figure 77: Mass Processing

Mass processing in production planning and control can be used anywhere where large amounts of data are being processed. It is mainly used in the automatic dispatching and deallocationof operations for predefined work centers in the background. For example, you can specify that the pool of orders for specific work centers is automatically dispatched at the start of each week. Mass processing is possible with any overall profile. The following profiles may affect mass dispatching when you call up the overall profile: • • •

Selection profile Strategy profile Time profile

The requirements grouping and planning do not influence the individual capacities. Note the material availability after a mass dispatching or mass rescheduling. This can be done using a collective availability check.

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Lesson: Capacity Leveling in Table Form

Figure 78: Tabular Capacity Planning Table

The tabular capacity planning table has the following display types: • •

Work center/capacity with available capacity, load, dispatched and pool for several periods Several work centers/capacities with available capacity and load for several periods

The tabular capacity planning table can be called up for the work center view, the individual capacity view and the order view. Available capacities and distributed capacity requirements are displayed. The unit of display for the available capacity and capacity requirements is specified in the evaluation profile. The tabular capacity planning table is divided into a resource section and a requirements section. The resource section contains the following: Name of the work center or the capacity and capacity category, dispatching periods, dispatched capacity requirements and requirements in a pool that have yet to be dispatched. In the requirements section, you can display requirements that have already been dispatched and/or have not been dispatched yet.

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Figure 79: Dispatching Procedure

The main function of capacity leveling is to dispatch operations. Operations are dispatched in order to fix them at a point in time when there is sufficient capacity for them to be carried out. If you have set the Finite scheduling indicator in the strategy profile, the system looks for remaining available capacities depending on the planning direction. If necessary, the user can specify another work center during dispatching. The work center cannot be locked or marked for deletion. Operations with the “dispatched” status can only be moved using the planning table after an order has been changed. A planning log is written for all planning activities. If errors occur during dispatching, the process can be terminated (you can make this setting in the strategy profile). With midpoint scheduling, the operations preceding and following an order are scheduled backwards or forwards, respectively, starting from a dispatched operation.

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Figure 80: Finite Scheduling

When using finite scheduling to dispatch operations, the system takes into account the current capacity loads of the capacities. In finite scheduling, only those capacities for which the Relevant for finite scheduling indicator has been set are taken into account. By not setting this indicator, you can exclude a capacity with sufficient available capacity from finite scheduling. Conflicts that arise between the operation dispatched and other operations in the order that have been dispatched and/or with the order itself do not lead to an automatic dispatching correction. For each operation to be dispatched, the system checks whether remaining capacity is available for the operation at the date determined. If the operation has suboperations relevant to scheduling, the system also looks for available capacity for these suboperations. If there is sufficient available capacity, the system dispatches the operation. If there is insufficient capacity, the system moves the operation to a date when it can be processed without any capacity problems. You can set the search direction to fowards in the strategy profile using the Planning direction indicator. The period for the search for remaining available capacity is specified in the time profile in the Planning period section.

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Scheduling Types Explain the scheduling types. Explain how the system determines basic dates and then schedules the operations within the basic dates. If the operations do not fit within the basic dates, the system implements reduction strategies (provided they have been defined). If the operations still do not fit within the boundaries of the basic dates, the system can adjust the basic dates using current date scheduling. Midpoint and finite scheduling are purely leveling functions in R/3. Customizing: Production → Capacity Requirements Planning → Operations → Scheduling → Define Scheduling Parameters for Production Orders Lead Time Scheduling - Finite Scheduling Explain the difference between lead time scheduling and finite scheduling. Explain the prerequisites for finite scheduling.

Figure 81: Time profile

The time profile defines the following time periods: Database read period, evaluation period and planning period. All the time periods are specified relative to the current planning date (positive/negative). You can enter the date in various ways. All the requirements that lie partly or entirely in the database read period are read.

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Lesson: Capacity Leveling in Table Form

The evaluation period must be less than or equal to the database read period and reflect the range of capacity requirements records (KBED records) that have been read. The planning period represents the range of the KBED records to be dispatched and must be less than or equal to the evaluation period. The date for dispatching backlog is a date to which all capacity requirements records are dispatched that are in backlog at this time. This provides an overview of the operations that have been delayed. It is used for the tabular capacity planning table, that is, for the display per period.

Figure 82: Dispatching Variants (Tabular)

This slide represents the four possible variants for determining the dispatching date. The third variant distinguishes between internally processed operations (maintenance orders and networks) and operations that are subdivided into operation segments (production orders). The dispatching date for: Internally processedorders according to the strategy profile is: • •

earliest/latest start date dependent on the distribution key

Operations with operation segments ( always with the latest start date for the operation) The first variant allows you to change the date, time and work center.

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The fourth dispatching variant can only be carried out on the graphical capacity planning table, and is dealt with in detail in the unit on "Capacity Leveling in Graphical Form". To ensure that operations are not dispatched automatically on the graphical or tabular capacity planning table, set the "Date entry when dispatching" indicator in the strategy profile. If this indicator is set, the system displays a dialog box in which you specify the dispatching date when you execute the Dispatch function. Capacity Leveling Measures Summarize the capacity leveling measures. Caution: When dealing with a work relocation from one work center to another, you must use the standard value key of the new work center. Therefore, note that the two work centers affected have the same standard values, as the calculations may otherwise be wrong. Capacity Leveling Interfaces Explain the basic differences between capacity planning tables and tabular capacity planning tables. The tabular capacity planning table displays the requirements in periods. Therefore, the duration of the operations within the order is unclear. For example, an operation can be carried out over more than one period and it would be necessary to check each period (or to look at the order itself) to determine the duration of the operation. This may be entirely acceptable if the course participant’s company is not interested in seeing the duration of the operation but would rather see the data in the form of a "pool" of requirements. The duration of the operations is displayed in the capacity planning table. You can double-click an object to view the details. Explain the various views (work center, individual capacity and order view) in capacity leveling. Mention that you will be discussing the tabular planning table in this unit and that the capacity planning table will be covered in the Capacity Leveling in Graphical Form unit. Tabular Capacity Planning Table Graphical Capacity Planning Table A limited adjustment is possible in the tabular planning table, but more can be changed in the capacity planning table (graphic). With the capacity planning table (graphic), you can almost adjust the entire display. Each section is described as a "chart". You can use up to eight charts for each table. Dispatching Procedure

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Lesson: Capacity Leveling in Table Form

The most important function of capacity leveling is the dispatching of operations. Operations are dispatched at a time when there is sufficient capacity. Depending on whether you want to dispatch the capacity, operations can be dispatched based on an unlimited available capacity or on the existing available capacity. The available capacity that is still available is calculated from the difference between the available capacity and the requirement that is already dispatched. When dispatching operations, you can enter another work center if necessary. However, this work center must also be selected when you call the planning table.

Demonstration: Tabular Planning Table and Dispatching Procedure Explain the different methods of dispatching, in particular, in the tabular capacity planning table. Leveling → Work Center View → Planning Table (Tabular). 1. 2. 3. 4. 5. 6. 7.

8. 9.

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Execute leveling at work center R-V99 and R-L99, plant 1000 Settings → Change view Settings → Screen type → Wide screen Execute dispatching by selecting the capacity requirement and choosing Dispatch. Deallocate the requirement again. Execute dispatching manually using the Dispatch Manually function. Make sure that you point out the date in the dialog box. Briefly show the Strategy profile and execute a dispatching operation using the Date entry when dispatching strategy. Point out the difference compared to the Dispatch Manually function. Plan a requirement in another period and at another work center. Display the status and the change of work center in the order by selecting the requirement and then choosing Order.

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Lesson: Capacity Leveling in Table Form

Exercise 9: Tabular Capacity Planning Table Exercise Duration: 30 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Carry out capacity leveling with the tabular capacity planning table

Business Example As a capacity planner in your company, you want to simulate capacity leveling for particular work centers with the tabular capacity planning table and then save the final result.

Task: Carry out capacity leveling with the tabular capacity planning table for the R-M##, R-V## and R-L## work centers (only for the 002 capacity category). 1.

Call up the tabular capacity planning table from the work center view and specify your three work centers. Take care in specifying the selection criteria of the other input fields. Logistics →Production →Capacity Planning → Leveling →Work Center View → Planning Table (Tabular) Use the Multiple selection button to enter the three work centers. In the Capacity category field, enter capacity category 002.

2.

Before you choose Execute, save the selection criteria that you have entered as a variant. Use V-## as “Variant name” and Group ## as “Meaning”. Goto → Variants → Save as variant

3.

Look for the capacity requirements for the R-V## work center and change to the display view for just one requirements type. Settings → Change view Scroll to the R-V## work center

4.

To see the latest start dates for the capacity requirements in the lower chart, switch to a wide screen display for the planning table. Settings → Screen type → Wide screen Continued on next page

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5.

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Dispatch the operation of a production order with the first requirements date for the planned R-V## work center. Select the requirements line and choose Dispatch.

6.

Only display those requirements that have been dispatched. Settings → Requirements Filter → Dispatched Requirements

7.

Go back to all of the requirements on the R-V## work center and dispatch another operation of a production order. However, this operation should not be rescheduled on the R-V## work center, but on the R-L## work center. Select the requirements line and click on the arrow button until you reach the R-L## work center. Select this work center too and choose Dispatch.

8.

Look at the dispatching log and analyze the planning situation at the R-L## work center. Choose Planning.

9.

Branch from the tabular capacity planning table to the production order and look at the changed operation and the operation status. Double-click the order number and choose Operation overview to see the changed operation. The work center was changed and the operation status DSPT, for dispatched, was set. Click on the yellow arrow to return to the tabular capacity planning table and save the rescheduling. Now save the results of your simulated planning.

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Lesson: Capacity Leveling in Table Form

Solution 9: Tabular Capacity Planning Table Task: Carry out capacity leveling with the tabular capacity planning table for the R-M##, R-V## and R-L## work centers (only for the 002 capacity category). 1.

Call up the tabular capacity planning table from the work center view and specify your three work centers. Take care in specifying the selection criteria of the other input fields. Logistics →Production →Capacity Planning → Leveling →Work Center View → Planning Table (Tabular) Use the Multiple selection button to enter the three work centers. In the Capacity category field, enter capacity category 002. a)

2.

Before you choose Execute, save the selection criteria that you have entered as a variant. Use V-## as “Variant name” and Group ## as “Meaning”. Goto → Variants → Save as variant a)

3.

Look for the capacity requirements for the R-V## work center and change to the display view for just one requirements type. Settings → Change view Scroll to the R-V## work center a)

4.

To see the latest start dates for the capacity requirements in the lower chart, switch to a wide screen display for the planning table. Settings → Screen type → Wide screen a)

5.

Dispatch the operation of a production order with the first requirements date for the planned R-V## work center. Select the requirements line and choose Dispatch. a)

6.

Only display those requirements that have been dispatched. Continued on next page

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Settings → Requirements Filter → Dispatched Requirements a) 7.

Go back to all of the requirements on the R-V## work center and dispatch another operation of a production order. However, this operation should not be rescheduled on the R-V## work center, but on the R-L## work center. Select the requirements line and click on the arrow button until you reach the R-L## work center. Select this work center too and choose Dispatch. a)

8.

Look at the dispatching log and analyze the planning situation at the R-L## work center. Choose Planning. a)

9.

Branch from the tabular capacity planning table to the production order and look at the changed operation and the operation status. Double-click the order number and choose Operation overview to see the changed operation. The work center was changed and the operation status DSPT, for dispatched, was set. Click on the yellow arrow to return to the tabular capacity planning table and save the rescheduling. Now save the results of your simulated planning. a)

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Lesson: Capacity Leveling in Table Form

Lesson Summary You should now be able to: • Use the leveling function of the tabular capacity planning table.

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Lesson: 194

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Available Capacity Lesson Duration: 120 Minutes

Lesson Overview This lesson deals with the options for available capacity maintenance.

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

Maintain available capacity. Maintain and assign shift sequences.

Explain the most important work center data for capacity planning. You should note that “capacities” can refer to a number of things, provided that the capacities can be expressed in time units. Pooled capacities are defined as master data and can then be assigned to one or more work centers. If you create a default capacity in Customizing, this capacity is automatically copied to the relevant field when you create a work center.

Business Example You must make capacity available in the production process. This can be defined differently for each workday, depending on the plant calendar. Therefore, you use intervals for capacities to increase the available capacity for periods where capacity requirements are high. You can maintain these manually or using shift sequences.

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Lesson: Available Capacity

Figure 83: Work Center Data

The work center contains several groups of data that are located on different screens. This example only shows the most important data for capacity planning.

Figure 84: Available Capacity at the Work Center

The reference indicator is set in the work center for the available capacity of a pooled capacity and, for this reason, cannot be changed. The available capacity of both an external and a default capacity is copied to one capacity category and can be changed there.

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A reference indicator can also be set for an external capacity. Planning Details at the Work Center/Capacity Explain the work center settings in the capacity header. Available capacity at the work center When configuring capacities, you can define default values that are copied to the work center when it is created. You can copy or reference the available capacity at the work center, create specific capacity data for this work center or assign pooled capacities to the work center. From Working Time to Operating Time Explain how standard available capacity is determined. The number of hours, minus the break times, multiplied by the capacity utilization equals the productive operating time. The productive operating time multiplied by the number of individual capacities equals the total available capacity at the work center for this capacity category.

Figure 85: Using Key Shift Sequences to Maintain Available Capacity

Shift sequences and shift definitions can be used to maintain available capacity in detail for each capacity category, but only by using intervals of available capacity. Shift sequences and shift definitions can be created and selected for specific parts of Customizing using the Grouping key. In a shift definition, you define the work start, end and break times for all work centers.

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Lesson: Available Capacity

In shift sequences, you maintain the specific sequence of shift definitions for all work centers. By changing the shift definition, you can automatically change available capacities that have shift definitions.

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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: Available Capacity

Lesson Summary You should now be able to: • Maintain available capacity. • Maintain and assign shift sequences.

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Capacity Leveling in Graphical Form Lesson Duration: 45 Minutes

Lesson Overview This lesson deals with handling the detailed scheduling planning board with the various dispatching options through different planning strategies.

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

Use the detailed scheduling planning board. Use planning strategies.

Describe: • • • •

The detailed processing steps for dispatching The functions of rescheduling and deallocation The structure of the overall profile Handling linked to capacity leveling

Business Example In your production process, you want to level the capacity loads on the work centers. You need to carry out capacity leveling with the graphical capacity planning table using various planning strategies. In your production process, there are work centers that are overloaded with capacity requirements. Therefore, you try to ensure that the delivery dates are observed by forming an optimal dispatching sequence of the requirements.

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Lesson: Capacity Leveling in Graphical Form

Figure 86: Graphical Capacity Planning Table

The graphical capacity planning table facilitates the continuous detailed planning of capacity requirements over a period of time. The graphical capacity planning table consists of several charts arranged horizontally, in which the available capacity (operating time) and the capacity requirements (operation duration) are grouped according to various criteria and can be displayed on the same axis. For example, all the capacity requirements for one order, or all the capacity requirements that have been dispatched on one capacity, can be grouped together. Each chart can have its own title bar and comprises a table section and a diagram section: • •

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The table section contains information for identifying and describing the objects displayed in the diagram section. The diagram section has a window on the virtual time axis in which the available capacity and the capacity requirements are displayed in graphical form with the start and finish date. This window displays the same section for all the charts. You can change this section by adjusting the scale as much as you like.

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Figure 87: Capacity Leveling - Overall Profile

When you call up capacity leveling and capacity evaluations, all the necessary settings are taken from an overall profile. This overall profile can be a profile provided by SAP or a user-specific profile. For capacity leveling, the relevant overall profiles are tied to a menu option, but you can access them using the appropriate USER parameters. If an overall profile is called up for a graphical capacity planning table, the profile for the tabular capacity planning table and the period profile is not required. If an overall profile is called up for a tabular capacity planning table, the profile for the graphical capacity planning table is not required.

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Lesson: Capacity Leveling in Graphical Form

Figure 88: Structure of a Profile (Leveling)

The overall profile contains subprofiles with settings that fit together: There are seven subprofiles for the graphical capacity planning table and eight subprofiles for the tabular capacity planning table. The control profile specifies the type of presentation and the layout of the data. There are also indicators for restricted planning, setup time optimization and actions to start jobs. In the evaluation profile, you can specify the work center hierarchy name for the summarization of available capacity and requirements. You can also specify the distribution key. The strategy profile specifies the planning strategies for dispatching and rescheduling. The time profile specifies the period in which capacity requirements are read from the database. The list profile specifies the layout of the standard overview and the detailed capacity list. The selection profile specifies which sets are used to determine the layout of the various selection screens. When calling up the overall profile for leveling with the graphical capacity planning table, the system also uses the profile for the graphical capacity planning table.

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When calling up the overall profile for leveling with the tabular capacity planning table, the system also uses the profile for the tabular capacity planning table and the period profile. The period profile specifies the periods in which the loads are represented. For example, a period can represent a day, a week, several days or several weeks.

Figure 89: Dispatching Operations

The dispatching dates are the start dates for the search for remaining available capacities in finite scheduling. You can specify them in several ways: • • •

Manual Entry Using the scheduled operation dates (lead time scheduling of the planned order or production order) Drag and drop using the mouse

Finite scheduling is a special type of lead time scheduling with a capacity availability check. Finite scheduling is only carried out for operations whose work centers have the Relevant for finite scheduling indicator. Midpoint scheduling can be executed either during simulation or when data is saved.

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Lesson: Capacity Leveling in Graphical Form

Figure 90: Strategy profile

The strategy profile is part of the overall profile for capacity planning and is used to define the parameters for an individual planning strategy. Different strategy profiles reflect different planning goals. You can switch the profile interactively during planning. If the indicator for cancelling dispatching in the event of an error is set, dispatching is cancelled if errors are detected when the system checks the operation dates and order dates. The system always writes a log.

Figure 91: Midpoint Scheduling I

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Midpoint scheduling is used for orders without relationships (such as production orders or maintenance orders) that are rescheduled during dispatching. Midpoint scheduling is a special type of lead time scheduling. The above example shows the process of dispatching an operation. Midpoint scheduling is always executed when at least one operation is dispatched. With midpoint scheduling, the order is not scheduled starting from the basic order start or order finish date. Instead, it is scheduled starting from the dispatched operation.

Figure 92: Midpoint Scheduling II

The example shows the process of dispatching a second operation in an order. If only one operation is dispatched, all the operations that precede it are scheduled backwards and all the operations that follow it are scheduled forwards. If more than one operation was dispatched, then the scheduling direction between the two dispatched operations depends on the scheduling direction that was selected during lead time scheduling. Midpoint scheduling is always necessary if an operation is shifted from its original time slot during capacity leveling, for example, due to an overload in the work center. As a consequence, the time slots for the operations must be adjusted to these new time slots, either before or after this operation. In contrast to lead time scheduling, in midpoint scheduling an order is not planned using the basic order start date or order finish date.

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Lesson: Capacity Leveling in Graphical Form

Demonstration: Capacity Planning Table, Midpoint Scheduling 1. 2. 3. 4. 5. 6.

Leveling → Order View → Planning Table (Graphical) Level with work center R-V99 Dispatch by selecting the requirement and choosing Dispatch. Move the dispatched requirement in the diagram chart. Deallocate the requirement. Also demonstrate the tasks from the exercise.

Figure 93: Check Report/Overall Profile

The overall profile consists of a series of individual profiles and can be a standard profile provided by SAP or a user-specific profile. As Customizing for the overall profile for capacity leveling is very complex, errors frequently arise when changes are made or new profiles created. A check report (transaction CMCH) provides a simple tool for error analysis for an overall profile. The check report lists the profiles of the overall profile on the screen. The system highlights profiles with errors. By double-clicking a highlighted profile, the profile hierarchy is expanded and possible errors displayed. The long text for the error message specifies how to remove the error and refers to the relevant transactions in Customizing.

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You can call the check report in the graphical capacity planning table by choosing Settings → Profile. By calling the check report with transaction CMCH and the menu options Edit → Assign colors, you can highlight errors in objects affected (for example, missing parts in the ATP check). An overall profile can be accessed with the user parameters CYA – CYP individually for every user. Explain the overall profile and the use of the user parameters CYA - CYP. Summarize the dispatching variants. Explain the procedure for dispatching operations. Rescheduling/Deallocating Hint: If the order quantity is changed, the system automatically deallocates all dispatched operations of this production order. The user must dispatch them again. During simulation, the original data is overwritten during a rescheduling operation to other work centers or dates are overwritten if a date is rescheduled. Caution: During the deallocation, the original dates are recovered if the indicator for adjusting basic dates has not been set.

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Lesson: Capacity Leveling in Graphical Form

Exercise 10: Planning Strategies Exercise Duration: 20 Minutes

Exercise Objectives After completing this exercise, you will be able to: • Select the graphical objects that belong together. • Carry out dispatching without gaps.

Business Example Task 1: Call up the capacity planning table with your selection variant V-## to carry out dispatching without any gaps at the work center R-L##. Logistics → Production → Capacity Planning → Leveling → Work Center View → Planning Table (Graphical) Choose Get variant to select your selection variant. 1.

To be able to select all the operations for the work center R-L## for dispatching, you must select the SAPSFCSS10 selection key. Edit → Select → Selection

2.

Using the selection key, select all of the operations for the work center R-L## and schedule them with a common start date for dispatching. In the table part of the lower chart, search for the first row with the work center R-L## and select this operation in the diagram section of the lower chart. Edit → Select → Objects that belong together Go to the strategy profile and set the switch for Date entry when dispatching. Choose Dispatch and confirm the dialog box with the suggested dispatching date. Scroll in the graphics area to see if a commitment was executed for the dispatch date?

3.

Why must this planning strategy be selected? _____________________________________________________ Continued on next page

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Now deallocate the second operation and make sure that the work center still has a commitment without any gaps. Choose the scale “Hourly period split from the menu” Settings → Scale. In the strategy profile, set the Close gaps until end of planning period indicator and deallocate the second operation. Consider the closing of gaps during deallocation.

5.

Complete the planning by saving the planning table.

Task 2: 1.

If the operation is rescheduled, you want to ensure that this operation is only dispatched on the scheduled date and the basic order date remains unchanged. In the following list, only select the dispatching strategies, with their dependencies, that guarantee this condition: - Date entry when dispatching - Finite scheduling - Midpoint scheduling - Cancel dispatching due to error - Use operation floats - Use float bef. prod. - Use float aft. prod. - Plan. direction forwards - Operation date check - Change planning direction Hint: Use the F1 input help if required.

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Lesson: Capacity Leveling in Graphical Form

Solution 10: Planning Strategies Task 1: Call up the capacity planning table with your selection variant V-## to carry out dispatching without any gaps at the work center R-L##. Logistics → Production → Capacity Planning → Leveling → Work Center View → Planning Table (Graphical) Choose Get variant to select your selection variant. 1.

To be able to select all the operations for the work center R-L## for dispatching, you must select the SAPSFCSS10 selection key. Edit → Select → Selection a)

2.

Using the selection key, select all of the operations for the work center R-L## and schedule them with a common start date for dispatching. In the table part of the lower chart, search for the first row with the work center R-L## and select this operation in the diagram section of the lower chart. Edit → Select → Objects that belong together Go to the strategy profile and set the switch for Date entry when dispatching. Choose Dispatch and confirm the dialog box with the suggested dispatching date. Scroll in the graphics area to see if a commitment was executed for the dispatch date? a)

3.

Why must this planning strategy be selected? _____________________________________________________ a)

4.

To achieve dispatching without any gaps at a work center, all operations must have the same start date at the time of dispatching. If this is not the case, the operations are generally dispatched on the scheduled date.

Now deallocate the second operation and make sure that the work center still has a commitment without any gaps. Choose the scale “Hourly period split from the menu” Settings → Scale. In the strategy profile, set the Close gaps until end of planning period indicator and deallocate the second operation. Continued on next page

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Consider the closing of gaps during deallocation. a) 5.

Complete the planning by saving the planning table. a)

Task 2: 1.

If the operation is rescheduled, you want to ensure that this operation is only dispatched on the scheduled date and the basic order date remains unchanged. In the following list, only select the dispatching strategies, with their dependencies, that guarantee this condition: - Date entry when dispatching - Finite scheduling - Midpoint scheduling - Cancel dispatching due to error - Use operation floats - Use float bef. prod. - Use float aft. prod. - Plan. direction forwards - Operation date check - Change planning direction Hint: Use the F1 input help if required. a)

For dispatching within the basic order dates, define the strategy profile as follows: • • • • •

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Finite scheduling YES Cancel dispatching due to error Consider operation floats and float before production with a backward planning direction Consider float after production with forward planning direction Switch planning direction Operation date check

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Lesson: Capacity Leveling in Graphical Form

Lesson Summary You should now be able to: • Use the detailed scheduling planning board. • Use planning strategies.

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Unit Summary

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Unit Summary You should now be able to: • Review the basic functions of capacity planning • Use the options of capacity evaluation. • Explain the development of capacity requirements • Explain the reduction of capacity requirements • Use the leveling function of the tabular capacity planning table. • Maintain available capacity. • Maintain and assign shift sequences. • Use the detailed scheduling planning board. • Use planning strategies.

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Test Your Knowledge

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Test Your Knowledge 1.

What essential elements of capacity planning must you consider during the implementation of the SAP ERP business application?

2.

What options for capacityevaluation does the SAP ECC system provide?

3.

Which essential data has an effect on the calculation of the capacity requirement of an operation?

4.

Which essential functions reduce the capacity requirement of an operation ?

5.

What forms of capacityleveling does the SAP ECC system provide?

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6.

What essential functions must capacity requirements planning provide to ensure an active balance between available capacity and capacity requirements?

7.

What essential functions of capacityleveling does the SAP ECC system provide?

8.

In which detail profile of an overall profile do you use most of the functions of capacity leveling discussed under point3?

9.

What options for providing available capacity exist in the work center?

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Test Your Knowledge

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Answers 1.

What essential elements of capacity planning must you consider during the implementation of the SAP ERP business application? Answer: • • • •

2.

Available capacity in a work center Capacity requirements (created with lead time scheduling (orders) Capacity evaluations Reduction of capacity leveling capacity requirements

What options for capacityevaluation does the SAP ECC system provide? Answer: • • • •

3.

Simple evaluation (lists, graphics, diagram) Extended evaluation Order information system (PP-SFC) Shop Floor Information System (LIS)

Which essential data has an effect on the calculation of the capacity requirement of an operation? Answer: • • •

4.

Formulas (maintained in the work center) Operation control key (maintained in the routing) Standard values (maintained in the routing)

Which essential functions reduce the capacity requirement of an operation ? Answer: • •

5.

Confirmation of an operation Setting a specific status

What forms of capacityleveling does the SAP ECC system provide? Answer: • • •

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Mass processing (dispatching, deallocation) Tabular capacity planning table Graphical capacity planning table

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What essential functions must capacity requirements planning provide to ensure an active balance between available capacity and capacity requirements? Answer: • • • • • •

7.

Sequence planning (operations) Date postponement (order) Available capacity increase Use of alternative work centers (planning) External assignment of operations Lot reduction/splitting

What essential functions of capacityleveling does the SAP ECC system provide? Answer: • • •

8.

Finite scheduling (search for available capacity for an operation to be scheduled) Midpoint scheduling (entire order) Optimal setup time for dispatching

In which detail profile of an overall profile do you use most of the functions of capacity leveling discussed under point3? Answer: Strategy profile

9.

What options for providing available capacity exist in the work center? Answer: • • • • •

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Standard available capacity (maintained in the work center) Interval of available capacity (differs from standard available capacity) The use of central shift sequences The use of pooled capacity The use of reference capacity

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Course Summary

Course Summary You should now be able to: • •

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Describe basic shop floor control procedures and functions and understand simple scenarios in the SAP System Use capacity planning functions for your consulting activities

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Course Summary

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Appendix 1 Summary

Overview of Production Types

Figure 94: Overview of Production Types (Basic Functions)

Use these slides to provide a comparative overview of the detailed functions of the different production types. It must be emphasized that the individual production types do not exclude each other in an application case; rather, depending on the conditions, it is possible to combine them.

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Appendix 1: Summary

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Legend: SFC

= Shop Floor Control = shop fabrication = discrete manufacturing with production orders

PI

= Process industry = manufacturing with process orders

REM

= Repetitive Manufacturing = period-based production

(1)

Possible under certain conditions

(2)

For planned order only

(3)

Backflush only

(4)

Valid period only

(5)

Linked to final confirmation

(6)

No reservations

(7)

No shop floor papers, only quantity papers (production lists) and operational method sheet

(8)

Quantities and activities only

(9)

For reporting point backflush only, for make-to-stock only Scheduling does not normally involve checking the available capacity. Capacity scheduling is possible for production/process orders. (Forward with check for free capacity)

Figure 95: Overview of Production Types (Special Functions)

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Appendix 1: Summary

(1)

By-products only

(2)

At goods receipt of finished product

(3)

At goods issue of component

(4)

Active ingredient management can be implemented together with material quantity calculation

(5)

In the standard system, only with Cost Object Controlling. As of EhP4, there is no longer a restriction.

(6)

At goods receipt using confirmation

(7)

Not with approved process orders

(8)

Simple or parallel discontinuation possible

(9)

EhP4 provides enhanced functions using Outsourced Manufacturing

Figure 96: Overview of Production Types (3)

(1) Possible using BAPI (2) Only possible based on execution steps (xSteps) as of ECC 6.0 + Enhancement Package 3

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Figure 97: Overview of Production Types (Integration)

(1) Outsourced Manufacturing contains enhanced functions for the external assignment of operations (external processing) with or without using the system component SAP Supply Network Collaboration (SAP SNC) based on ECC 6.0 + EhP4 and (if SNC is required) SCM 7.0. (2) As of ECC 6.0 + EhP3, the Production Supervisor role enables almost complete browser-based management of production orders (based on an Enterprise Portal). (3) The Production Supervisor role can also be used for process orders and repetitive manufacturing as of ECC 6.0 + EhP4. Furthermore, you can use NetWeaver Business Client (NWBC) instead of the Enterprise Portal as user interface.

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Appendix 1: Summary

Information About Follow-Up Courses

Figure 98: Information About Follow-Up Courses (1)

For a complete overview of all courses offered, see the SAP curriculum plan. You can easily find this information on SAP Service Marketplace or on the SAP homepage.

Figure 99: Information About Follow-Up Courses (2)

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Figure 100: Information About Follow-Up Courses (3)

Information on the Internet •

SAP Help Portal

•

– http://help.sap.com/ SAP Service Marketplace

•

– http://service.sap.com/ SAP Supply Chain Management

•

– http://www.sap.com/scm/ SAP Educational Services

•

– http:// www.sap.com/education/ Software partners

•

– http://www.sap.com/partners/software/ SAP Shop –

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http:// www.sap.com/shop/

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Appendix 2 References

Figure 101: References

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Appendix 2: References

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Appendix 3 Detailed Functions of Capacity Requirements Planning

Figure 102: User Parameters - Capacity Evaluation

An overall profile can be accessed with the user parameters CY1 - CY7 individually for every user.

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Appendix 3: Detailed Functions of Capacity Requirements Planning

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Figure 103: Rescheduling/Deallocating

You can reschedule operations that have already been dispatched by specifying a different date and/or a different work center. If you specify another work center, you must have selected this work center when you called up the planning table. When you deallocate operations, the current dispatching date and the "Dispatched" status are cancelled. The order is rescheduled. The system can close gaps that arise when operations are rescheduled or deallocated. It does this by moving operations according to the Close gaps key in the strategy profile. Changing the order quantity automatically results in deallocation of the operation. On the capacity planning table, the ATP logic can be used to carry out material availability checks for production orders. The system checks the availability of components at order level, that is, for all operations in the production order for the requirements dates. The result of the availability check can be analyzed in the planning log.

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Appendix 3: Detailed Functions of Capacity Requirements Planning

Figure 104: Other Functions

To change the time periods on the initial screen, choose the button Time profile. You can display the shift calendar for a capacity on the capacity planning table. The features of the shift period split and the relevant time fence are determined in the time scale profile. You can specify that the system is to hide non-work periods that are common to all capacities on the capacity planning table. To aid orientation, you can insert date markers in the diagram section of the capacity planning table. In Customizing for capacity leveling (under Define chart sequence), you can specify that multiple commitment is automatically displayed in the capacity planning table. On the planning tables, you can copy data from other structures to production orders and maintenance orders. For example, you can copy material data from the MARA structure in the tabular capacity planning table (text lines) and in the graphical capacity planning table (table section) using the layout key. If a work center is being maintained, the capacity at the work center carrying out the maintenance is not available at this time. This capacity is assigned an unchangeable load. To do this, you must make the appropriate entry for the system condition in the maintenance order. To call up a dialog box displaying data on the work center, choose Extras Planning info system.

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Other Functions Explain the enhanced functions using the slide notes for capacity leveling. • • • • • •

•

Changing time periods: Choose Change time profile on the selection access. Generate a shift period by selecting Settings → Shift Calendar → Show Hiding break times: Settings → Break times → Hide(or in SPRO, determine scale of time axis with the Hide non-working times indicator) Inserting date markers: Edit → Insert date markers Displaying multiple commitments: Edit → Multiple commitment → Show Maintenance Times of Capacities: In a maintenance order with plant condition 0 (out of order), a black bar is displayed in the planning table for repaired capacity. The capacity can no longer be planned in this time period. Planning - information functions: Extras → Planning info system

Figure 105: Planning Direction

The planning direction determines the search direction for remaining available capacities if no capacity is available at the required time. With automatic dispatching, the system searches forwards for a possible dispatching date within the planning period. When the Change planning direction indicator is set, the system changes the planning direction when searching for remaining available capacity if it does not find any in the planning period in the planning direction. If this indicator is not set, dispatching occurs in the past.

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When the system dispatches operations at the earliest point in time, it does not take into account the dispatched dates of the operation. With this planning strategy, you can achieve a capacity commitment without any gaps by using the Plan. direction forwards setting.

Figure 106: Insert Operation/Close Gaps

On the capacity planning table, operations can be inserted in a capacity commitment that has already been dispatched. The operations that have already been dispatched are moved according to the planning direction without changing the sequence. The capacity must not allow multiple commitments. The Close gaps function is used when a dispatched operation is deallocated or rescheduled. Depending on the planning direction indicator in the strategy profile, the operations that follow or precede the rescheduled or deallocated operation are rescheduled (moved) to close the gap that has arisen. You can define the direction and period concerned in the strategy profile. Therefore, this rescheduling either finishes at the next gap or at the end of the planning period. You can achieve a schedule without gaps by using the Dispatch at earliest point in time function.

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Figure 107: Handling Queue Times

To specify that the system is to check the operation dates and use the queue time, you must set the following indicators in the strategy profile: • •

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Operation date check Use operation float. This means that the operation can only be moved within the earliest and latest dates (queue time). The queue time is calculated according to the settings in the strategy profile.

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Figure 108: Using Order Floats/Operation Floats

To check the operation dates and use all the order floats, the following indicators must be set in the strategy profile: • •

• •

Operation Date Check Use operation float. This means that the operation can only be moved within the earliest and latest dates. The queue time is calculated according to the settings in the strategy profile. Indicator: Use float before production Indicator: Use float after production

The time periods are extended by the duration of the order floats and operation floats. Dispatching at the earliest circumstance means that the system starts with “"today"” and searches for the first available capacity for the operation. Explain the use of the queue time and the order float. Demonstration: Planning Strategies and Queue Times Demonstrate dispatching with the different planning directions. Carry out a planning without gaps and demonstrate the insertion of an operation and deallocation with overall profile SAPSFCG011. Capacity Planning → Leveling → Variable → Online

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Show the following data and indicator at work center R-P99 • • • • • • • •

Working time for capacity category 002(7:00 - 15:00) Indicator Relevant for finite scheduling. No indicator for “Can be used by several operations” Queue time is 1 hour Create two production orders for material R-F199, 55 pieces with start date in a week and 51 pieces with start date one day later. Call up the planning table for work center R-P00 and capacity category 002. Choose the Hourly period split. Schedule the later order (51) in such a way that the start date is after the queue time, that is, before the end date of the requirement to be dispatched (55).

Strategy 1 for dispatching with a termination • • •

Do not set the indicator for a forward planning direction because the queue time can only be considered during backward scheduling. Set the indicators Use operation floats, Operation date check and Cancel dispatching due to error. Dispatch requirement (50) automatically. After you terminate dispatching, call the planning log.

Strategy 2 with the Use operation floats indicator deactivated and the forward direction planning indicator. •

The requirement is planned after the requirements that have already been planned. Deallocate the requirement for strategy 3 again.

Strategy 3 with forward planning direction indicator deactivated. The requirement is dispatched before the requirements that have already been planned.

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Figure 109: Sequencing 1

You define the dispatching sequence for the selected operations using the sort key in the dispatching sequence field. The operations must have the same start dates. Once sequencing and dispatching have taken place, the setup standard values are only reduced if the relevant strategy is set in the strategy profile. You can also use other sort criteria by assigning sequence numbers in the order header (planned order and production order).

Figure 110: Sequencing 2

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In this example, the dispatching sequence is determined by the setup optimization function instead of the sequencing key. During setup time optimization, the standard value for the setup is changed. As a result, the values for the duration and capacity requirements are recalculated using the formulas. The setup group key and setup group category are a prerequisite both for setup time optimization and for the sort sequence. An initial setup state field has been integrated into the strategy profile. This field allows you to maintain a predecessor operation for the first operation to be dispatched so that a setup time adjustment can be executed. Operations are also deemed predecessor operations if they lie outside the planning period but within the evaluation period.

Figure 111: Standard Overall Profiles for Capacity Leveling

The values in brackets specify the relevant user parameters where you can predefine a profile.

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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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