7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 1/12

Introduction to SAP PPPI - SAP Process Manufacturing

 

Introduction to SAP PPPI - Process Manufacturing

 

My definition to "Process manufacturing" is that, it is a form of an industry type,where the products once manufactured, cannot be  easily dis-assembled. It is also really

not possible to rework the ill-manufactured end products, back in to raw materials. For 

example products such as food products, chemicals, medicine, Towels, Paper, Steel etc. 

With the above definition of a process industry in perspective, SAP offers SAP PPPI or 

SAP PI which can be used to implement business processes in a process industry.

There are a many key differences between Process manufacturing and discrete

manufacturing with respect to manufacturing processes and SAP offerings.

 

Speaking of the key differences, the following points are slated here andexplained in the next section below: 

•  A Master Recipe is one of the key differences and all the individual

differences revolve around the master recipe. SAP PP-PI has a task list

called as a Master Recipe vis-a-vis the routings in the SAP PP. SAP uses

the master recipe when creating the process order. The purpose Routings

and the Master Recipe is equal to a large extent, like scheduling, capacity

generations, generating planned costs and component scheduling.

Though the major difference between the master recipe and the routing is

- a) embedding of the BOM in the task list through the use of production

versions, b) material quantity calculations, c) process management which

defines a standard interface between SAP and the shop floor to

communicate production and execution data.

• Process Management allowing an interface between SAP and the shop

floor destinations.

• Process order related documentation.

 

Key Differences between SAP PPPI - Process Manufacturing & SAP PP -Discrete Manufacturing:

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 2/12

 

 A detailed analysis of these difference is made all over the SAP PP PIDocumentation. Though a start is made here in this section to bring about thedifferences clearly before deep diving in to the article in subsequent pages. Thedifference between SAP PP and PP PI is made only as an overview: 

a) Production Versions and their use in Master Recipe 

Vis-à-vis the routing or rate routing, the master recipe collects the operations andthe BOM together in one master data through the use of production version. Theproduction version is exploded in the recipe to pull in the material BOM. Bringing the BOM inside the task list helps in generating one more unique featureof a recipe called the “Material Quantity Calculations”. The material quantity

calculations helps to change the component quantities and the header materialquantity vis-à-vis each other and with respect to the values of the activeingredients (batch classification specifications) of the components and theheader material. Before creating the recipe, one should have a Production version created with atleast the BOM embedded in it, which will help adding the BOM to the recipe. 

Very Important Note – It seems to be a normal practice that the recipe groupnumber is added to the production version after it is created. So you may have to

maintain the production version information, firstly after the BOM creation andbefore the recipe creation and once after the recipe creation so as to assign theRecipe group number to it. 

b) The concept of phases and operations in a task list 

•  A master recipe carries a concept of operations assigned with phase’s vis-

à-vis discrete manufacturing which has only operation level details. The

operations are thus mere place holders of phases and carry no major 

importance in SAP PP PI.

• The introduction of phases helps the organization to break down the

activities on an operation (as phases) and detail them out.

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 3/12

• The standard values/activities like the set-up time or duration or machine

time etc; are assigned to the phases in process manufacturing unlike

discrete manufacturing where they are assigned to the operation itself.

This takes you to an obvious conclusion that the confirmation in process

manufacturing are carried out at the phase level rather than at operation

level.

• The concept of Relationships between phases of different operations or 

with the same operation or even between two different material recipes

helps in scheduling the process orders (as per the relations set-up). The

relationship between phases in SAP PP PI can be correlated with parallel

and alternate operation sequence set up in discrete manufacturing.

• The External operation processing is also carried out at the phase level

and not at the operation level.

• Though one can assign inspection characteristics to both operations and

phases.

• Even the components of the BOM in SAP PPPI, are assigned to the phases and

not the operations, thus strengthening the fact that the phases govern over the

operations.

• The work center or resource are assigned to the operation level and all the phases

assigned to the operation uses the same resource. A resource carries a QDR 

system, which is the address of an external control system to which data has to be

sent, in cases when the control recipe destination is an external process control

system. The QDR field can be configured in SAP.

• The set up of the "process management functionality in SAP PP PI" through

control recipe destination, process instruction categories and process message

categories is done at the phase level. You can assign a unique control recipe

destination to a phase and a set of process instruction categories which are

eventually downloaded to the respective destinations as control recipe. This is

explained in detail further down. 

c) The concept of Material list and Material Quantity Calculations in theMaster Recipe 

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 4/12

 As discussed in the above paragraph the master recipe has an added capabilityto bring in the material list or the BOM through the use of production versions.The presence of BOM in the recipe allows SAP PP PI to add a functionalitycalled as "material quantity calculations" for the header material as well as thecomponents, where in you can change the component quantities and the header 

material quantities based on the characteristics values of their respective batchclasses and through formulas written as macros.

 

d) Process Management 

The master recipe also comes with a feature called as the process management,which is primary differentiator between the Routing and the Recipe.

• This features allows a clear communication or interface between SAP andthe shop floor destination to communicate production or execution related

data between them. This interface is a standard SAP defined interface and

works with SAP sending process instruction categories to the destination

and the destination sending back execution data to SAP for updation in

SAP database.

• Every phase in a master recipe has a shop floor destination or control

recipe destination. The process instructions are assigned to the phases;

these process instructions carry process notes, order details, phase

details, component details, quality inspection details, goods receipt details.

The process instructions are bundled up into a control recipe and are sent

to the control recipe destination, which once sent to the shop floor 

operator or the process control system, helps them to with the detailed

information and instructions about the order and initiates a trigger to start

manufacturing activities.

• The process instructions also contains information on the Process

messages which are supposed to be sent back to SAP (data requests),

like the confirmation records for the order; goods issue records for the

order and goods receipts data for the order, inspection results for the

received goods etc. Eventually the processes messages post the data in

SAP tables using various BAPI’s and functional modules.

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 5/12

•  An “individual process instruction” for example – a process instruction for 

order information, contains characteristics like the order number, plant

code, order type, order start date, order finish date, order reservation

number, header batch number (if any) etc. These characteristics carry the

respective values. You can manually change/add the values or have them

populated by the system (for example for characteristics like order 

number, order start date, order type etc ;) as per the process design. The

characteristics used in process instructions to carry values of various

parameters are always assigned with a characteristics group called as

PPPI_INST.

• The process instructions can be assigned to the master recipe with

product or process specific values assigned in them or they can be

assigned to the control recipe destination itself. Assigning the process

instructions at the control recipe destination would automatically explode

them in the process order and this avoids the effort of individually

assigning them at the material/plant level master recipes. For process

instruction attached to the destination, you could still assign values to

them but they would not be material specific and would be very generic in

nature which is applicable to the processes carried out at the destination.

•

The Process instructions are bundled up in a control recipe which isdownloaded from SAP and sent the control system or the shop floor 

operator. The Recipient processes the process order and sends activity

completion process messages to the SAP system in the form of process

messages.

• Correlation – One can correlate the process instructions as an

examination Question Paper’ set for a particular grade with instructions

and questions in it. This question paper (as process instructions) is given

to each and every student belonging to a particular grade (a grade can bea control Recipe destination) along with the process message request to

answer the questions in a particular set time (consider the filled up answer 

sheet along with the Roll number and grade as process messages which

are requested back by the system). The students are expected to carry

out the activities of answering and appearing for the test and in return

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 6/12

submit the answer sheet as process message back to the examiner (the

examiner can be the SAP system which updates the completion

information and marks in SAP system).

• Standard SAP in SAP PPPI is designed to have the recipient as a shopfloor operator in SAP itself, who completes the order detailing and

manufacturing in PI SHEETS and sends back the process messages to

the SAP cockpits to process standard designed BAPI’s. On the other hand

if the recipient is a process control system outside of SAP, he can also

receive or request the instructions in a control recipe to aid in production

and send back the messages to SAP system through standard interfaces

designed for such integrations between SAP and the external shop floor 

control system.

Figure 1 

e) Use of Intra Materials in SAP PP PI

 

Use of Intra Materials in a key feature available both in process manufacturing and

discrete manufacturing; though it is predominantly talked about in process manufacturing

since SAP PPPI offers storage resources in between operations to store these intramaterials. Intra Materials are materials which are added to stock in between production

and removed from stock when they are issued to the next resource. 

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 7/12

 

f) Electronic Batch Record: 

SAP PP PI provides a Facility for documentation & Optical Archiving of the BatchRelated data of a process order or order related data for future references. You can

document or record all the process order related activities of the process order.

Control Recipe Destinations

 

Control recipe Destinations

 

Standard SAP has control recipe destinations which receive the processinstructions and using which the destination carries out the manufacturing and atthe end of which they send back the process messages to confirm their production activities or production status on a real time basis. The control recipe destinations are assigned to the individual phases of an

operation; which means that every phase in a master recipe can carry differentcontrol recipe destinations. One control recipe is created for a given destinationand order combination. The destinations or recipients of the process instructions can be SAPdestinations or external process control system destinations. If the destination isin SAP itself, then it can be a shop floor operator/operator group at a plant or aproduction line or shop floor operator/operator group for a specific activity,executing the phase; where as if the destination is an external process controlsystem outside of SAP, then the process instructions & process messages areinterfaced with that external system.

 The definition of the control recipe destination needs configuring the destinationtype, address of the destination (in external system, the address is the RFCdestination of the process control systems). 

Control

Recipe

SAP External Control System

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 8/12

Destination

 

1 & 4 Destination lies in SAP ERP

system

 

2 & 3 Destinations lies outside of SAP ERPsystem and is called as an ExternalControl System

 

Control Recipe Destinations Type 1 & 4 - Destination located in SAP ECCSystem 

For shop floor destinations which are in SAP itself, there are 2 different types of destinations called “1” and “4”, to represent them. The destination operator groupof type 1 receives all the process instructions & requested process messageswell arranged on an ABAP based sheet or screen called as a PI-Sheet (one for an order, for a destination). Whereas for a destination of type 4, a sheetcontaining all the process instructions and requesting process messages, wellarranged on a web based sheet browser based PI-Sheet is sent to the internaloperator/operator group. 

Note: An ABAP based PISHEET is shown below, if the same is set for a

destination type 4 – browser based PI-Sheet, then the sheet with the informationwould appear in a browser in HTML format. With Destination type there arestandard BAPI’s and connections working, which would process the messagesonce sent back to SAP by the respective destinations. 

Note: In configuration for the destinations of type 2 and 3, you can assignprocess instructions which would be automatically become a part of controlrecipe and would be downloaded to the external control system. Whereas for destinations of type 1 and 4, there is a provision to assign the processinstructions in a sequence (making a list of suitable instructions) which are

generated in the process order control recipe and subsequently downloaded tothe SAP operator/operator group.

Note: Transaction to create the Control Recipe destination is O10C. 

ABAP Based PISHEET

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 9/12

Order Information

Process order numberProcess order typePlant

Process order QuantityControl Recipe numberReservation NumberDestinationDate/Time 

10002569PI010002

1010000000002982356154301 – Shop Plant 000225th Dec 2010

Operation/Phase Information

Operation

Phase Description

StandardValues forthe order

Start Date& Time

FinishDate & Time

Destination

0010 0011 2 HR 25.12.2010 12:45:00

25.12.2010 14:45:00

01

0010 0012 1 HR 25.12.2010 14:45:00

25.12.2010 15:45:00

01

0020 0014 0.5 HR 25.12.2010 15:45:00

25.12.2010 16:15:00

01

Component Information

Operation

Phase Component

Description Qty UOM SLOC Batch

0010 0011 C1 C1 10 EA RM 0000000123

0010 0012 C2 C2 20 EA RM 0000000543

0020 0014 C3 C3 10 EA RM 000000021

3

Requesting Phase Confirmations

Operation

Phase Yield Scrap Set up Time

Machine Time

 Text Reason

 

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 10/12

 

Requesting Goods Issues

Component

Qty UOM SLOC Batch ComponentDescription

 Text Reason

C1 C1

C2 C2

C3 C3

Requesting Goods Receipts

Dynamic Function Call for MIGO_GR Transaction Code – Press here toaccess MB31 T - code

 

Control Recipe Destinations Type 2 & 3 - Destination outside of SAP(External Systems)

 

For control recipe destinations lying outside of the SAP system, i.e., externalprocess control systems or manufacturing execution systems lying outside of SAP, the process instructions are sent their through a standard designedinterface. There are majorly two control recipe destinations interacting withexternal process control systems, namely “2” and “3”. Destination type “2” is used when the SAP initiates the transfer or download of control recipe to the external process control system (Push case); whereas “3” isused when the transfer or download of control recipe is triggered by the external

control system (Pull case). Note - When the process control system is an external system, you can assignthe process instruction categories and have the system generate control recipesautomatically.

Note: In configuration for the destinations of type 2 and 3, you can assignprocess instructions which would be automatically become a part of control

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 11/12

recipe and would be downloaded to the external control system. Whereas for destinations of type 1 and 4, there is a provision to assign the processinstructions in a sequence (making a list of suitable instructions) which aregenerated in the process order control recipe and subsequently downloaded tothe SAP operator/operator group.

Note – For external control systems, it is required to define a RFC destination, soas to define the connections to the control system and enable SAP tocommunicate with the system. The transaction code to create is SM59. 

Figure 2

 

7/27/2019 Introduction to SAP PPPI

http://slidepdf.com/reader/full/introduction-to-sap-pppi 12/12

Figure 3