PLM114 Basic Data for Ma Nu Factoring

PLM114Basic Data for Manufacturing and

Product ManagementmySAP Product Lifecycle Management

Date

Training Center

Instructors

Education Website

Participant HandbookCourse Version: 2006 Q2Course Duration: 5 Day(s)Material Number: 50079412

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

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Copyright

Copyright © 2006 SAP AG. All rights reserved.

No part of this publication may be reproduced or transmitted in any form or for any purposewithout the express permission of SAP AG. The information contained herein may be changedwithout prior notice.

Some software products marketed by SAP AG and its distributors contain proprietary softwarecomponents of other software vendors.

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THESE MATERIALS ARE PROVIDED BY SAP ON AN "AS IS" BASIS, AND SAP EXPRESSLYDISCLAIMS ANY AND ALL WARRANTIES, EXPRESS OR APPLIED, INCLUDINGWITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR APARTICULAR PURPOSE, WITH RESPECT TO THESE MATERIALS AND THE SERVICE,INFORMATION, TEXT, GRAPHICS, LINKS, OR ANY OTHER MATERIALS AND PRODUCTSCONTAINED HEREIN. IN NO EVENT SHALL SAP BE LIABLE FOR ANY DIRECT,INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES OF ANYKIND WHATSOEVER, INCLUDING WITHOUT LIMITATION LOST REVENUES OR LOSTPROFITS, WHICH MAY RESULT FROM THE USE OF THESE MATERIALS OR INCLUDEDSOFTWARE COMPONENTS.

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

Typographic ConventionsAmerican English is the standard used in this handbook. The followingtypographic conventions are also used.

Type Style Description

Example text Words or characters that appear on the screen. Theseinclude field names, screen titles, pushbuttons as wellas menu names, paths, and options.

Also used for cross-references to other documentationboth internal (in this documentation) and external (inother locations, such as SAPNet).

Example text Emphasized words or phrases in body text, titles ofgraphics, and tables

EXAMPLE TEXT Names of elements in the system. These includereport names, program names, transaction codes, tablenames, and individual key words of a programminglanguage, when surrounded by body text, for exampleSELECT and INCLUDE.

Example text Screen output. This includes file and directory namesand their paths, messages, names of variables andparameters, and passages of the source text of aprogram.

Example text Exact user entry. These are words and characters thatyou enter in the system exactly as they appear in thedocumentation.

<Example text> Variable user entry. Pointed brackets indicate that youreplace these words and characters with appropriateentries.

2006/Q2 © 2006 SAP AG. All rights reserved. iii

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About This Handbook PLM114

Icons in Body TextThe 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'spresentation.

iv © 2006 SAP AG. All rights reserved. 2006/Q2

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ContentsCourse Overview ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Course Goals .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viiCourse Objectives ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Unit 1: Overview of Master Data for Product Management andManufacturing ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Types of Data in SAP ERP .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Use of Organizational Data and Master Data in Production... . . . .7

Unit 2: Organizational Data in Supply Chain Management.... . 21Plants .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Storage Locations.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27MRP Areas.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Unit 3: Material Masters ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Overview of the Material Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Creating a Material Master .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Classification of the Material Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Managing the Material Master. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Configuration of the Material Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Unit 4: Bills of Material .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Overview of the Bill of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132Managing Bills of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147BOM Reporting.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178Configuration of the Bill of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

Unit 5: Modeling the Manufacturing Process ..... . . . . . . . . . . . . . . . 213Modeling Manufacturing .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215Basic Work Center Data and Defaults .. . . . . . . . . . . . . . . . . . . . . . . . . . .221Capacities in the Work Center . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238Integrating Costing with the Work Center.. . . . . . . . . . . . . . . . . . . . . . . .250Configuring the Work Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

Unit 6: Task Lists..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281Overview of the Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282Creating a Routing and Material Assignment .. . . . . . . . . . . . . . . . . . .296Suboperations and User-Defined Fields ... . . . . . . . . . . . . . . . . . . . . . . .307Reporting and Mass Changes.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315

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Contents PLM114

Configuring the Routing .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327

Unit 7: Advanced Bill of Material Functions ..... . . . . . . . . . . . . . . . . . 339Phantom Assemblies ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341Co-Products and By-Products.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345Discontinuation and Substitute Parts in the Bill of Material. . . . .353Multiple and Variant BOMS .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369Mass Changes and the Product Structure Browser ... . . . . . . . . . .393

Unit 8: Advanced Routing Functions ..... . . . . . . . . . . . . . . . . . . . . . . . . . 405Modeling Complex and Flexible Manufacturing Processes .. . .407Modeling Alternative Manufacturing Processes... . . . . . . . . . . . . . . .418Reference Operation Sets .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431Lead Time Scheduling and Material Master Updates .. . . . . . . . . .441Time Components, Reduction Possibilities in the Routing ... . .450Trigger Points in the Routing .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464Scrap and Its Effects ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468Production Resources/Tools... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .480

Unit 9: Engineering Workbench ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493Structure of the Engineering Workbench .. .. . . . . . . . . . . . . . . . . . . . . .494Navigating in the Engineering Workbench .. . . . . . . . . . . . . . . . . . . . . .500Engineering Workbench Work Areas.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .516

Index ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531

vi © 2006 SAP AG. All rights reserved. 2006/Q2

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Course OverviewThis course will educate participants on how master data and organizational datais maintained in SAP ERP. Participants will learn how to create, manage, reportand configure the master data objects that are relevant to the production planningprocess. This will include:

� Plants� Storage Locations� Material Masters� Bills of Materials� Work Centers� Task Lists and Routings

Target AudienceThis course is intended for the following audiences:

� Project team members and employees responsible for configuring, creating,and maintaining the follow master data objects in SAP

� Plants� Storage Locations� Material Masters� Bills of Material� Work Centers� Task List/Routings

Course PrerequisitesRequired Knowledge

� Basic understanding of Supply Chain Management in SAP ERP

Recommended Knowledge

� Basic understanding of master data requirements in a production planningand execution environment

2006/Q2 © 2006 SAP AG. All rights reserved. vii

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Course Overview PLM114

Course GoalsThis course will prepare you to:

� Explain the organizational structures and basic data in Manufacturing andPlanning

� Describe the manufacturing functions that support materials and bills ofmaterials

� Describe the manufacturing functions that support work centers and routings� Participate in configuration decisions that ensure that SAP R/3 supports

company requirements� Describe some of the advanced modeling features in manufacturing and

planning using Bills of Materials and Task lists.� Describe the features of the Engineering Work Bench

Course ObjectivesAfter completing this course, you will be able to:

� Maintain material masters and bills of materials� Maintain routings and work centers� Assign material components to operations� Managed updates to various master data objects� Execute reports on various master data objects� Model various manufacturing options in the bill of material and routing� Maintain master data using the engineering work bench

SAP Software Component InformationThe information in this course pertains to the following SAP Software Componentsand releases:

� ECC 6.0

viii © 2006 SAP AG. All rights reserved. 2006/Q2

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Unit 1Overview of Master Data for Product

Management and Manufacturing

Unit OverviewThis unit introduces you to how master data will be used in supporting the SAPERP production planning and execution process. The different master data andorganizational data are discused at a summary level. Each object will be coveredin more detail in following lessons.

Unit ObjectivesAfter completing this unit, you will be able to:

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

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

Unit ContentsLesson: Types of Data in SAP ERP ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Procedure: Configuring SAP ERP ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Lesson: Use of Organizational Data and Master Data in Production ... . . . .7

2006/Q2 © 2006 SAP AG. All rights reserved. 1

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Unit 1: Overview of Master Data for Product Management and Manufacturing PLM114

Lesson: Types of Data in SAP ERP

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

Lesson ObjectivesAfter completing this lesson, you will be able to:

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

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

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

� Configuration data� Master data� Transactional data

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

2 © 2006 SAP AG. All rights reserved. 2006/Q2

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PLM114 Lesson: Types of Data in SAP ERP

Figure 1: Configuration in SAP ERP

During an implementation, the SAP ERP landscape will typically consist of threeservers: DEV (development), QA (quality assurance), and PROD (production).Each server may have several clients. The DEV server is where a sandbox clientwill exist, as well as the golden client, where the final configuration resides.

During the project, team members will try different iterations of configurationin the sandbox client and test the results. If the results meet the organizationsrequirements, they are configured again in the golden client. From there, the Basisteam moves it to the QA server for further evaluation. The Basis team will us atool called the Change and Transport System (CTS). This allows them to track theconfiguration changes from DEV to QA, and QA to PROD.

Once the configuration changes are moved to the QA server, integration testingwill take place within the PP module and within the other applications in SAPERP, such as materials management (MM) and Sales and Distribution (SD), forexample. Once fully tested in the QA system, the configuration will be transferredto PROD, or the production server/client.


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Configuring SAP ERP

1. Enter transaction code SPRO.

2. Select Reference IMG.

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

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

Figure 2: Master Data

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

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


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PLM114 Lesson: Types of Data in SAP ERP

Business users will be limited to creating, changing, or displaying data based ontheir role within the organization. During implementations, each business mustdetermine how the Product Lifecycle Management (PLM) process within SAPERP will integrate with their specific business processes.

As organizations change, so must the master data to support the business; thisneeds to be modeled properly within the SAP ERP environment.

Transactional DataEvery day, businesses perform tens of thousands of transactions that make thebusiness function. Some transactions are directly related to outside events withcustomers or suppliers. Other events are internal to the business and affect theinteraction between departments within a business or division.

Figure 3: Transactional Data

Within SAP ERP, all transactional data is related to some form of master data orconfiguration data. In the world of production planning, you will be executingplanning runs that will be generating replenishment suggestions, generatingproduction execution directions, or executing production confirmations. In SAPERP production planning, all transactional data typically revolves around thematerial master, bill of material, or routing.

In this class you will learn how master data works; however you may be askedto analyze how it works in conjunction with day-to-day business events ortransactions, such as a production order.


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Lesson Summary

You should now be able to:� Describe the types of data used in modeling and executing manufacturing

in SAP ERP


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PLM114 Lesson: Use of Organizational Data and Master Data in Production

Lesson: Use of Organizational Data and Master Data inProduction

Lesson OverviewIn this lesson you will be exposed to organizational data and its potential impacton production planning in SAP ERP.


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

Business ExampleAs a member of the project team, you must understand how organizationalstructures, production planning, and master data are used to develop anorganizational plan to support existing and future business.

Organizational Objects in Production PlanningThe foundation of the SAP ERP system is the organizational structure that will beconfigured at the early stages of your company's implementation of the software.All other configuration or master data will be built on top of the organizationalstructures.


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Figure 4: Organizational Structure

To better understand the structure, you must familiarize your self with severaldefinitions:

ClientThe client is a unit within an SAP ERP system that is self-contained both inlegal and organizational terms, and in terms of data, with separate masterrecords and an independent set of tables. From a business viewpoint, theclient represents a corporate group, for example.The client is the highest hierarchical level in the SAP ERP system.Specifications or data that you make and enter at this level apply to allcompany codes and all other organizational units. Therefor, you do not haveto enter the specifications and data in the system at client level more thanonce. This ensures a uniform data status.Access authorization is assigned on a client-specific basis. A user masterrecord must be created for every user in the client in which he or she wishesto work. If the Client field has not been prepopulated, each user mustspecify a client key when logging on to an SAP ERP client. The client keyis uniquely defined in the system and is a three-digit number. In this way,the user specifies the client in which he or she wishes to work. All userinput is stored and separated by client.The processing and evaluation of data is likewise carried out on aclient-specific basis.


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Company codeA company code is the smallest organizational unit of external accountingfor which a complete, self-contained bookkeeping system can be replicated.This includes the entry of all events that require posting to the accounts andthe creation of a complete audit trail for balance sheets and profit-and-lossstatements. A company code represents an independent unit producing itsown balance sheet, for example, a company within a corporate group (client).You can set up several company codes in one client in order to keep separatesets of financial books. You can use a special Customizing function to copya company code. In the process, company-code-dependent specifications areadopted for your new company code.A company code is defined in the system by means of a four-characteralphanumeric key that is unique in the client.

PlantThe plant is an organizational unit within logistics that subdivides anenterprise from the viewpoints of production, procurement, and materialsplanning.

Storage LocationThe storage location is an organizational unit that facilitates thedifferentiation of stocks of materials within a plant. Inventory managementon a quantity basis is carried out in the plant at storage-location level. Thephysical inventory is also carried out at this level.A storage location is defined by means of a four-character alphanumeric keythat is unique in the plant.

Organizational units are tightly linked to each other to quickly process the relevantdata for a business area. For example:

Plant 1000 is assigned to company code 1000Company code 1000 is assigned to controlling area 1000

Therefore, whenever a transaction involving cost occurs in plant 1000, the relevantrecords in controlling area 1000 are automatically updated. The valuation area isthe organizational level at which material quantities and values are managed. It isessential for product costing that a valuation area exists for each plant.

Within each valuation level, you can differentiate between values and quantitiesfor valuation (in-house production and external procurement) by using differentvaluation types. In Customizing for materials management (define valuation type),balance sheet valuation is set up at company-code or valuation-area level.

Selection of valuation-area level automatically causes the creation of a valuationarea for each plant. To use product costing and order costing, inventory must bevaluated at plant level.


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Purchasing OrganizationOutside of production planning, other areas of the SAP ERP system needadditional configuration to support their specific functional needs. In addition tothe client and company code requirements, purchasing requires an additionalorganizational structure.

Figure 5: Purchase Organization

A purchasing group is a key for a buyer or a group of buyers who are responsiblefor certain purchasing activities. Internally, the purchasing group is responsible forthe procurement of a material or class of materials. Externally, it is the principalchannel for an enterprise's dealings with its vendors.

Note: The purchasing group is not assigned to other units of the enterprisestructure in SAP ERP.

Purchasing groups are not defined in Customizing for the enterprise structure, butin Customizing by choosing Materials Management→ Purchasing→ CreatePurchasing Groups.

The purchasing organization is an organizational unit within logistics thatsubdivides the enterprise according to the purchasing requirements. A purchasingorganization procures materials or services, negotiates conditions of purchase withvendors, and assumes responsibility for these transactions.


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You can incorporate purchasing into the company structure by assigning thepurchasing organization to a company code and to plants. This means thatyou can take into account whether purchasing is organized on a centralized ordecentralized basis in your company. You can have a combination of these twoorganizational forms.

You can assign several purchasing organizations to one company code.However, a certain purchasing organization can only belong to one companycode. You can decide not to assign the purchasing organization to a companycode (cross-company-code purchasing). There is an m:n relationship betweenpurchasing organizations and plants. In other words, you can assign several plantsto one purchasing organization, and one plant to several purchasing organizations.

Sales OrganizationSimilar to the purchasing side of an organization, the group responsible for saleshas additional unique business requirements.

Figure 6: Sales Organization

The sales organization is responsible for selling and distributing goods andservices. It is liable for the products sold and responsible for a customer's rights ofrecourse. The sales organization can be used to represent a regional, national, orinternational subdivision of a marketplace in which products are sold.

A sales organization is uniquely assigned to a company code, however a companycode may have more than one sales organization assigned to it. If the Sales andDistribution module is used, at least one sales organization must be defined.

The sales organization is the highest summation level in sales statistics. Customermaster data will be created for each sales organization. Documents createdthroughout the Sales and Distribution process (order, delivery, and billingdocument) will belong to a sales organization.


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A distribution channel is a means through which saleable materials or servicesreach the customer. A distribution channel is assigned to a sales organization. Asales organization may have more than one distribution channel assigned to it. Ifthe Sales and Distribution module is used, at least one distribution channel mustbe defined and assigned to a sales organization.

A distribution channel allows customers to be treated differently depending on thechannel they are assigned to. For example, a customer assigned to a wholesaledistribution channel may receive preferred pricing compared to a retail distributionchannel customer.

A sales organization can have several divisions assigned to it, but must have atleast one division. A division is used to group materials and services. A divisioncan represent a product group or product line, which allows:

� Restricted price agreements to a certain division� Statistical analysis by division

A sales area is a unique and allowable combination of a sales organization,distribution channel, and division. Each Sales and Distribution document isassigned to exactly one sales area. This assignment cannot be changed. A salesarea can belong to only one company code. This relationship is created by theassignment of the sales organization to the company code in Customizing.

The shipping point is the organizational element that manages your shippingactivities. Each outbound delivery is processed at a shipping point.

A shipping point can be a physical location, for example, a loading dock, a mailroom, or a railroad depot. It can also be a logical location, for example, a group ofemployees responsible for processing next-day deliveries or less-than-truckloadorders.

Shipping points are assigned to plants. A shipping point should have physicalproximity to the plant to which it is assigned. More than one shipping point canbe assigned to a plant. Several plants can also have a shared shipping pointassigned to them, for example, several plants in same physical proximity sharingthe same railroad depot.

Master Data Objects in Production PlanningOnce your company has established an organization structure, the differentbusiness areas can proceed with developing the application-specific master datato activate the necessary functionality required to run the day-to-day activitiesof your business.


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Figure 7: Master Data for Production Planning

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

� Material master� Bill of material� Work center� Routing/task list

Material MastersMaterial Master Record: Definition

The material master contains information on the materials that a companyconstructs, procures, manufactures, stores, and sells. The information is stored ina database that is a central source of data on materials. The material master recordintegrates data from different areas of a company.


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Figure 8: Material Masters in SAP ERP

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

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


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Figure 9: Bills of Material In SAP ERP

Bills of material will be integrated with the material master and can be used inconjunction with routing to schedule a more precise usage point. These BOMsare used in material requirements planning, production, procurement, and productcosting.

A BOM consists of header material and BOM items (components). The basequantity in the header material specifies the finished production quantity on whichthe component quantities are based. BOM items indicate individual parts andassemblies, which are identified by their material numbers.

BOMs are single level. A BOM item can also contain components, so thatmulti-level production can be described by the single-level BOMs from thefinished product, assemblies, or assemblies of the assemblies (and so on). Inaddition to stock items, which flow into the finished product, a BOM can alsocontain documents or text items.

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


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Figure 10: Work Centers in SAP ERP

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

Task Lists and RoutingsA routing defines operations and the sequence in which they are carried out. Thefollowing is also defined in the routing:

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


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Figure 11: Routings in SAP ERP

A routing shows operations in a sequence and acts as a template for productionorders. Each step defines the work center in which specific work will beaccomplished. The planned time for each operation is stored in the routing asa standard value.

These standard values are the basis for:

� Lead time scheduling� Product costing� Capacity planning


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Lesson Summary

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


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PLM114 Unit Summary

Unit SummaryYou should now be able to:� Describe the types of data used in modeling and executing manufacturing

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


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Unit 2Organizational Data in Supply Chain

Management

Unit OverviewIn this unit, you will be introduced to how your company's organization structurewill be mapped out in SAP ERP. In addition, you will see how this organizationalstructure will affect your master data structures and maintenance process.Lastly, you will be introduced to the concept of configuration in the SAP ERPImplementation Guide (IMG).


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

Unit ContentsLesson: Plants .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Procedure: Configuring a Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Lesson: Storage Locations .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Procedure: Configuring a Storage Location .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Lesson: MRP Areas .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Procedure: Using MRP Areas .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35


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Unit 2: Organizational Data in Supply Chain Management PLM114

Lesson: Plants

Lesson OverviewIn this lesson you will learn about plants in relation to the organizational structureand how they are integrated into master data.


� Describe the purpose of a plant in SAP ERP

Business ExampleYour company currently has many locations where they store and manufactureproducts. In order to make the most of out of your implementation, you must beaware of how to model various installations in SAP ERP. You want to learn moreabout how the SAP ERP plant will fit your supply chain model.

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

Figure 12: Definition of a Plant


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PLM114 Lesson: Plants

A plant may be defined for different purposes, depending on the role the plantwill have in the organization. In Sales and Distribution, a plant can representthe location from which finished goods materials are stored and distributed. Aplant may also be the location from which services are rendered. In materialsmanagement, a plant represents a location where material flow is managed. Stockrequirements are managed from inbound and outbound perspectives. Materialstock is consumed, planned and purchased in the plant. In production, a plantrepresents a manufacturing facility where materials are produced.

Figure 13: Plant in the Organizational Structure

When creating a new plant, you can use the plant copy function. In the process,all entries in the plant table and all Customizing and system tables that dependon it (and in which the plant occurs as the key) are taken into account. A plantis defined in the system by means of a four-character alphanumeric key thatis unique in the client.

Once a plant is configured, it must be assigned to several other organizationalelements to assure cross-functional integrations. Here is an example of where theplant will be assigned:

� Company code� Business area� Sales organization� Purchasing organization

Plants are often determined as single geographical locations where thosenecessary business functions must be tracked. In certain situations, companies cancombine several locations that are closely geographically located into one plantto minimize the organizational hierarchy. Due to tax reasons, some companies


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will split a single location into multiple plants. For example, companies will selltheir finished goods to another company immediately after production, whilethe distribution location belongs to another facility. Both plants may exist in thesame geographical location, but remain as two separate plants reporting to twoseparate company codes.

As mentioned earlier, the plant is the key focal point for production planning. Allmaster data, planning, and execution activities are defined and performed the plantlevel. Some examples of these dependencies are:

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


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PLM114 Lesson: Plants

Configuring a Plant

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

2. Choose Define Plant. Select Plant 1000 and choose Details.

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

4. Choose Copy Org. Object.

5. Enter 1000 in Copy From field and P114 in Copy To field and chooseContinue (Enter).

6. Once completed, exit to the main menu.

7. Choose Enterprise Structure→ Assignment→ Logistics-General→ Assignplant to company code.

Review Company code 1000.

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

8. Choose Enterprise Structure→ Assignment→ Logistics-General→ Assignplant to company code.

Review Company code 1000.

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


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Lesson Summary

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


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PLM114 Lesson: Storage Locations

Lesson: Storage Locations

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


� Describe the purpose of a storage location in SAP ERP

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

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

Figure 14: Storage Locations in SAP ERP

As with all organizational elements, storage locations are configuration and aredefined in the IMG. A storage location is defined by means of a four-characteralphanumeric key that is unique in the plant.


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The enterprise structure is created through the assignment of organizational levelsto each other. A client may therefore contain several company codes. In turn, acompany code may contain several plants. However, a plant can only ever belongto one single company code in the SAP system.

Hint: Since the plant key is unique in a client, and a plant can only belongto one company code, by specifying the plant you simultaneously specifythe company code.

Several storage locations may be assigned to a plant, but when a certain storagelocation is assigned to a plant it forms a compound key. Storage locations aredefined especially for a plant and are thus assigned to this plant. The storagelocation key need only be unique within a plant. Within a client, the same key canbe used for different storage locations, since when you specify a storage locationyou always have to specify the plant as well.

Figure 15: Storage Location Address

Note: To create storage locations, in the IMG, choose Enterprise Structure→ Definition→ Materials Management→ Maintain Storage Location.Here you can create a storage location in reference to a plant.


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Upon creating a storage location, you will define a unique four-character value.This value is alphanumeric, so a company could create an exhaustive number ofstorage locations for each facility. In addition, when creating a storage location,companies have the opportunity to define a different address for each storagelocation. This may be done for one of several reasons:

� The storage location represents a sub-contractor location where inventoryis held.

� The storage location represents a company facility with a different shippingaddress.

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

The material master record is automatically extended the first time a goods receiptis posted for the material. All data specific to the storage location is updated in thematerial master record. The system can be configured in this way in Customizingby choosing Materials Management→ Inventory Management and PhysicalInventory→ Goods Receipt→ Create Storage Location Automatically.

In this step, you specify whether the automatic creation of storage location data isallowed for goods receipts. This is advisable if you want to post a goods receiptwithout having to maintain the storage location view of the material master recordin advance. First, you have to allow automatic creation per plant. You then have toexplicitly allow the creation of storage location data for each movement type. Thestorage location data is only created if the quantity is posted to �standard� storagelocation stock. It is not created for receipts into a special stock (for example,into sales order stock).

Note: The standard system is set in such a way that the storage locationdata is created automatically for all types of receipts (goods receipt with orwithout reference, stock transfers, initial entry of stock balances, reversalof goods issues, and so on).

To manually create storage locations, enter the storage locations for a materialmaster record collectively. This is much less time-consuming than entering thedata for each storage location individually. This can be performed from theapplication menu path by choosing Logistics→ Production→ Master Data→Material Master→ Other→ Enter Storage Locations (MMSC).

Once a material exists in a storage location users, will see a Storage location viewon the material master. In addition, they will be able to make settings for materialrequirements planning (MRP) at the storage-location level in the MRP 4 view.


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Configuring a Storage Location

1. In the IMG, choose Enterprise Structure → Definition → MaterialsManagement→ Maintain Storage Location.

2. Choose Execute.

3. Enter Plant P114 and choose Continue.

4. Choose New Entries.

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

6. Select the new storage location and select the folder Addresses of Storagelocations twice.

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

8. Choose Save.


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Lesson Summary

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


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Lesson: MRP Areas

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


� Describe the purpose of an MRP area in SAP ERP

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

MRP Areas in SAP ERPDuring the blueprint process of an implementation, when teams are consideringthe organizational structure, the will have to consider not only financial impactsbut those of the logistics planning and execution.

Figure 16: Organizational Structure Overview


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PLM114 Lesson: MRP Areas

In many situations, the logistics side of the business has specific requirementsfrom customers to keep inventory and demand separate from other streams ofdemand. This may be due to subcontracting requirements or storing spare/serviceparts separate from the rest of the facility. One option companies have is creatinga separate plant, but from a configuration standpoint this requires a lot of overheadand possible maintenance while having no positive financial impact.

MRP areas are not part of the physical organization structure, but can use thestorage locations within a plant to break up requirements and inventory duringplanning.

Figure 17: MRP Areas

MRP areas are defined as part of MRP configuration. There are three types ofMRP areas: plant, storage location, and Vendor (subcontractor). We will onlyfocus on the storage location aspect since that can affect the modeling of yourorganizational structure.

Note: To find MRP Areas in the IMG, choose Production→ MaterialsRequirements Planning→ Master Data→ MRP Areas→ Define MRPAreas.


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When creating MRP areas, you must specify the MRP area type, plant, andreceiving storage location for Type 2 (storage location). Companies have theoptions of assigning one or more storage locations to each MRP area. Once anMRP area is defined, users must assign material masters to the MRP areas theywish to segregate from the rest of the plant.

Note: When demand is placed at the storage location level � either throughsales order, demand management, or via some dependent demand � ifthe material master is assigned to an MRP area that contains the storagelocation, all demand and inventory are kept separate from the plant.


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PLM114 Lesson: MRP Areas

Using MRP Areas

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

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

Field Value

MRP Area OS01-P114

Description Out Sided Storage

MRP Area Type 02 - Storage Location

Plant P114

3. Press ENTER.

4. Enter receiving storage location OS01and choose Save.

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

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

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


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Lesson Summary

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

Related InformationFor more information as it pertains to production planning, see online help orSAP course SCM240.


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PLM114 Unit Summary

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


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Unit 3Material Masters

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


� Describe the organizational layout of the material master� List the prerequisites to creating material masters� Use various methods to create material masters� Describe the request process with interactive forms and explain how it might

benefit your business� Describe how the material master can use classification to include

company-specific fields� Describe how classification can be used for batch management of inventory� Describe how classification can be used for variant configuration� Describe different ways to update or change the material master� Demonstrate the mass maintenance features of the material master� Describe how the material master can be updated using the request processes

with interactive forms for materials management� Describe the archiving and deletion process for the material master� Describe the process of influencing the field characteristics of the material

master� Describe Process of configuring the screen layout of the material master� Set up a customized material master in Customizing� Test the settings by creating a material master

Unit ContentsLesson: Overview of the Material Master.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41


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Unit 3: Material Masters PLM114

Procedure: Organizational Levels of the Material Master. . . . . . . . . . . . . . 45Lesson: Creating a Material Master .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Exercise 1: Creating Material Masters... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Lesson: Classification of the Material Master .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Exercise 2: Material Classification .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Lesson: Managing the Material Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Exercise 3: Managing Material Masters .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Lesson: Configuration of the Material Master .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Procedure: Setting Up Screen Sequences ... . . . . . . . . . . . . . . . . . . . . . . . . . .115Exercise 4: Material Types, Field Control and Material Status ... . . . .119


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PLM114 Lesson: Overview of the Material Master

Lesson: Overview of the Material Master

Lesson OverviewIn this lesson you will learn about the material master at a high level and itspurpose in SAP ERP.


� Describe the organizational layout of the material master

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

Introduction to the Material MasterThe material master contains information on the materials that a companyconstructs, procures, manufactures, stores, and sells. The information is stored ina database that is a central source of data on materials. The material master recordintegrates data from different areas of a company.

Figure 18: The Material Master


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

The material master can be valid for many different areas within the business.All data is maintained in several centralized tables, based on relevance to theparticular part of the organizational structure. The material master is used byall SAP R/3 logistics applications. It controls whether a material is purchased,produced, or sold.

Every area of responsibility can have a material master view. Because differentuser departments in a company work with the same material, and each of thesedepartments wants to store different information on the material, you cansubdivide material master data according to the department to which it belongs.Each department then has its own material master record view and is responsiblefor the data being correct.

The data that you maintain in the following views is used by production planning(PP) functions:

� The basic data view includes general data, such as the material number,material description, base unit of measure, and technical data.

� The classification view contains user-defined class assignments for amaterial.

� The materials planning view contains plant-specific data used inprocurement planning.

� The scheduling view contains plant-specific data used for schedulingmaterials for production.


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Figure 19: Organizational Levels of the Material Master

Some material data is valid on all organizational levels and other data is onlyvalid for specific levels. So that the material data can be managed centrally in thecompany without clogging up your data with redundant information, the materialmaster is structured hierarchically, reflecting a company's structure. In SAP ERP,the only elements that directly impact production planning are client, plant, andstorage location.

General material data that applies to the whole company is stored on client level.This includes material descriptions, base units of measure, and conversion factorsfor alternative units of measure. This data is contained in the tableMARA.

All data that applies to a plant and its assigned storage locations is stored on plantlevel. Examples of this kind of data are MRP and forecasting data. This data iscontained in the tableMARC.

All data that applies to a specific storage location is stored on storage locationlevel. This is mainly storage location stock. This data is contained in the tableMARD.


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

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


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Organizational Levels of the Material Master

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

2. Select the MRP 1 screen and enter plant 1000.

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

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


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Lesson Summary

You should now be able to:� Describe the organizational layout of the material master


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PLM114 Lesson: Creating a Material Master

Lesson: Creating a Material Master

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


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

benefit your business

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

Prerequisites for Creating Material MastersPrior to creating a material master, several pieces of information must be known inorder to properly create a material master record in SAP ERP.

The person who creates the first view of each material master record must define:

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


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Figure 20: Material Types in SAP ERP

When you create a material master record, you must define material type for thematerial. The material type determines which business processes (such as sales,production, or purchasing) and functions (use of material in BOM or routing) areallowed for a material. The selection of the material type should not be takenlightly, as a wrong choice can have serious impacts.

The material type is a configurable item and is usually controlled by costingor Inventory Management due to the large impact is has on those areas of animplementation.


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Figure 21: Material Type Configuration

To be able to manage different materials according to the company's standardrequirements, materials with the same characteristics are divided into groupsand assigned to a material type. Examples of material types are raw materials,semi-finished products, and finished products.

When you create a material master record, the material type determines:

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

Additionally, the material type determines the procurement type of a material, forexample, whether the material is produced in-house, procured externally, or both.

Moreover, the material type determines which accounts are posted to when amaterial enters or leaves the warehouse.


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Figure 22: Industry Sector

The industry sector determines which data fields and screens are available forinput during material master maintenance. Industry sector is one of severalinfluencing factors. In the configuration of the material master, industry sector canact as one key in specifying whether a field is required, changeable, display only,or hidden. In addition, industry sector is used in configuration to determine whatviews and what sequence a user can display the material master.

Note: From within any of the Create, Change, or Display transactions,users can access the Defaults→ Industry Sector menu. This transaction isuser-specific, and can control the default industry sector as well as hidethe industry sector once a default is set.

Figure 23: Material Numbering

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


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a number internally, you do not enter any material number when you create amaterial master record. Until you save the material master record, the system setsthe internal material number in the appropriate field. When you save, the systemautomatically assigns the next available number.

The type of number assignment that is allowed depends on the material type andis defined in Customizing. First, you have to maintain the number range groups.You then assign the material types to the groups.

Note: Material numbering is defined at the client level.

You can assign an interval to only one group. You can also change the currentnumber of an interval manually.

Figure 24: Storing and Displaying the Material Number

During configuration, your company can decide how to view material masters.The material master field has a maximum of 18 characters. You can configurationa template to provide breaks in the material number, for example, 123-456-789.In addition, if you do not intend to use all 18 characters from the beginning, youcan specify whether leading zeros are to be displayed.

The data you enter for material number conversion determines the way materialnumbers are displayed in dialog functions and printouts only. This means that theinformation is stored in the database unconverted.

Caution: The display format for the material number is effective forall clients.


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

Figure 25: Units of Measure

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


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All units of measure in the SAP system that are additional to the base unit ofmeasure are grouped together under the title �alternative units of measure.� Thefollowing alternative units of measure are supported:

� Base unit of measure (Basic Data 1): Stock keeping unit. All other unitsof measure you use are converted to the base unit of measure. If there is nostandard formula to convert an alternative unit of measure to the base unit ofmeasure, you must enter the conversion factor for the units of measure inmaterial master maintenance.

� Order unit (Purchasing): Unit of measure used for ordering the material.This is the default unit for purchasing functions.

� Sales unit (Sales: sales org 1): Unit of measure used for selling the material.This is the default unit displayed in the sales order. You can also changethis unit in the sales order.

� Production unit (Work Scheduling): Unit of measure to be used in thereceipt of production. When you create a production order for a material, anda production unit has been entered in both the material master record and inthe routing, the system checks whether the quantity entered in the productionorder falls within the lot size range in the routing.

� Unit of issue (Work Scheduling/Whse Mgmt 1): Unit of measure forissuing the material from stock. Use this unit for goods issue and stockmovement transactions. You can also use this unit for the BOM item quantity.

Note: The design engineering department uses the base unit of measure asa rule.

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


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Figure 26: Unit of Measure Groups

For materials that have similar weight and dimension characteristics, you cangroup together several units of measure in a unit of measure group and assignthe group to a material. For each unit of measure in the group, you can enterthe conversion factor to the base unit of measure. You maintain unit of measuregroups in Customizing for the material master (Logistics - General).

Caution: The base unit of measure must not be entered in the unit ofmeasure group.

Creating New MaterialsWhen a company needs to create a new material master record, they have to matchthe process to the SAP ERP transactions. Listed below are several options forcreating new material masters


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Create Material Master Record: Transactions

� MM01 - Create (general) immediately� MM11 - Create (general) planned for the future� MM#1 - Create with special material type immediately

(# = R, B, F, I, H, U, N, V, L, S, K, P, W and G)� CEWB - Engineering workbench

Hint: The engineering workbench (EWB) enables material masterrecords to be created for new BOM items. The material is usually createdimmediately. It is generally the case that BOM maintenance cannot workwith material master records that are only planned.

Note: As soon as a material master record is created with MRP dataand a valid MRP type, this material is then automatically included inthe planning file, which is extremely important for MRP. When loadingthe data from a legacy system, the transaction does not create planningfile entries.

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

Figure 27: Creating Materials with Default Values

If you copy from another material, values from the material master are copied tothe new material master record that you are creating, where you can overwritethem.

Hint: As of SAP R/3 4.6X, you can select the Create Views Selectedcheckbox to automatically create all views that exist in the referencematerial (departments). Previously, each view (department) had to beviewed individually. This is no longer necessary.


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Material Master Record Defaults

To access material master data efficiently, you can:

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

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

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

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

� MM01 - Create (general) immediately� MM11 - Create (general) planned for the future� MM#1 - Create with special material type immediately

(# = R, B, F, I, H, U, N, V, L, S, K, P, W and G)� CEWB - Engineering workbench� MM17 - Create new data records (views) immediately in mass maintenance� MM50 - Create new views for extendable materials

Hint: The above comments on the engineering workbenchalso applyhere. Ensure that when using MM#1 transactions, the material type of theexisting material master record is appropriate for the transaction. This isnot important for transactions MM01 and MM11, as the system readsthe material type from the material master and, in doing so, overwritesany data entries.

Creating a Material Using MRP Profiles and MRPGroupsThe MRP profile allows users to set default values for MRP data fields and todetermine whether the values can be changed during material master maintenance.If a change is made to a default value in an MRP profile and the field cannot bechanged using material master maintenance, the system automatically changesthe field value in all material masters linked to that specific MRP profile.


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The forecast profile allows users to set default values for forecast data fields and todetermine whether the values can be changed during material master maintenance.If a change is made to a default value in a forecast profile and the field cannot bechanged using material master maintenance, the system automatically changesthe field value in all material masters linked to that specific forecast profile.

In addition to the MRP profile, users creating MRP views can use and assign MRPgroup to the material in the material master (MRP 1 view). The MRP group isdefined in configuration under the MRP section. It is used to apply field values toa large number of materials.

Caution: When using MRP groups, be aware that the field values do notappear in the material master. This is different from the MRP profile.

Creating Material Masters Using Request Processeswith Interactive FormsIn most organizations, one of the major obstacles is defining and managing aprocess for creating master data. A huge range of forms are used on a daily basisin all types of business, especially for processing requests and approvals. Usingpaper forms for such processes is singularly inefficient. Delivery and submissionis very time-intensive, and usually requires direct contact with an employee.Under such conditions it is difficult for the managers responsible to follow theprogress of a process.

As of SAP ERP ECC (2004), a new function called Interactive Forms is availablefor Product Lifecycle Management (PLM) . This new functionality enables you tocomplete the processing of products and materials considerably more efficiently,as well as to implement company-specific standards for quality throughout thecourse of the process.


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Figure 28: Creating Master Data with Interactive Forms

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

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

The electronic forms contain data on the person who makes the request and thereason for it. Additional process-specific data is added by experts, for example:important product or material data in the New Product request form, or whetherstock data should be considered in the change process in the Product Changerequest form. The data is presented clearly, tailored to the area of responsibility ofthe employee, and supplemented with notes explaining the process.

You process the forms in standardized processes that are defined in the processtemplate. The temporal and logical sequence of the processing steps is linked to theevaluation of conditions. For example, the data required for a particular step mustbe complete and correct before the subsequent step can be started. The employeesresponsible, such as the person who makes the request, experts, and managers,are automatically integrated in the separate process steps. Although the employeeprocesses the form offline, information is available from the SAP system.

For example, the employee can use the input help for entering system data, andthe entries are checked for validity. The manager is notified that the request formneeds approval through the Control Center of the Guided Procedures component


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in the materials management service directory. This is where the managereither approves the data for entry in the SAP system, or rejects it and initiates anotification to the person who made the request.

The design of the forms, as well as the processes, have been modeled with thefunctions of the Guided Procedures component (Web Application Server (WAS)→Composite Application Framework (CAF) ®→ Guided Procedures (CAF-GP)).The following overview includes information about where you can find thedocumentation for the Guided Procedures (CAF-GP) component.

� Documentation for the application, with information on softwarerequirements:

SAP Library at http://help.sap.com/: SAP NetWeaver → CompositeApplication Framework (CAF)→ Guided Procedures (CAF-GP).

� Installation guide: SAP Service Marketplace at http://service.sap.com/in-stguides: Installation and Upgrade Guides→ SAP xEPM 1.0 Installationand Configuration Guide.

Simulation: New Product Request (from RTK-ERP)View the following simulation to learn more about this lesson:FileName: 573DF48ABE268D41B6D44449F7C39E28~NewProductRqst_IAF.sim


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http://help.sap.com/

http://service.sap.com/instguides



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Exercise 1: Creating Material Masters

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create defaults to be used with creation of material masters� Create a material master without any template data� Create a material master using Copy From functionality

Business ExampleAs the product development engineer, you are responsible for controlling themanagement of the material master in your company. To start this process, youneed to understand the different ways that a material master can be created. Youwant to find out which method matches with your business process.

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

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

2. Your recent position will only have you creating materials for a certainsection of the company. Therefore, set your user's default for theorganizational values Plant 1000, Sales Organization 1000 and DistributionChannel 10, and only display organizational levels on request.

3. Your recent position will only have you creating materials for a certainbusiness areas within the company. Therefore, set your user's default for thematerial master views for which you are responsible for creating. Set BasicData 1, MRP 1 - 4, Work Scheduling, Accounting 1, and Costing, to alwaysbe selected and select Create views selected so if you use any materials astemplates, you will not have to look at all views to create the material.

4. Create an MRP profile for rapid and secure maintenance of MRP data fromthe material record.

Continued on next page


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Create an MRP profile, SF##, with the description Semi Finished Group## for use in creating material masters with the material type Semi-FinishedProduct. Use the parameters in the following table for this exercise.

Note: Solution steps will appear after the table in the Solutionssection.

Data of MRP profile SF##Field Name Maintenance

StrategyDefault Value

MRP Type Fixedvalue

PD

MRP controller Default 0##

ABC Indicator Fixedvalue

A = important material

In-house productiontime

Default 5 days

Scheduling marginkey

Default 002

Lot Size (MaterialsPlanning)

Fixedvalue

EX = exact

Purchasing group Default 000

Planning time fence Default 10 days

Component scrap in%

Default 1 %

Indicator:Backflush

Fixedvalue

2 = work center decides

Task 2: Creating Material MastersAs a design engineer, you will be required to create material masters every day.You will use the defaults created in the previous task to speed up the process. Inthis section, you will be required to create five material masters. This will includetwo finished products and three semi-finished products.

1. Your supervisor has given you the specs on a new pump that has just comeout of research and development. She has asked you to enter the materialmaster into the system so that one of your colleagues can begin building thebill of material. No material currently has the same attributes, so you will



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create the new material with no template data. Use the following data tosupport the creation of the new finished production: T-F## (Rotary PumpGR##) at plant 1000.

Note: Solution steps will appear after table in the Solutions section.

Entry Screen DataMaterial Number T-F##

Material Type Finished Product

Basic Data 1Material Description Rotary Pump GR ##

Base Unit of measure PC - piece

MRP 1MRP Type PD

MRP controller 0##

Lot Size EX - Lot for Lot

MRP 2In house Production 1

Scheduling margin key 001

MRP 3Strategy Group 10

Accounting 1Valuation Class 7920 - finished product

Price Control S-Standard Price

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



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

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

5. Your supervisor has given you the specs on a new centrifugal pump that hasjust come out of research and development. She has asked you enter thebasic data information of the new pump. The balance of the views will beentered at a later date. No material currently has the same attributes, so youwill create the new material with no template data. Use the following datato support the creation of the new finished product: T-F77## (CentrifugalPump GR##) at plant 1000.


Entry Screen DataMaterial Number T-F77##


Basic Data 1 Datamaterial Description Centrifical Pump GR ##


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


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Solution 1: Creating Material MastersTask 1: User DefaultsIn the role of an engineer, you are tasked with creating large quantities of materialmasters. To make the process run more efficiently, you will use default values andMRP profiles to expedite the creation of material masters. Set your organizationallevel, industry sector, and view defaults as instructed below. Once completed, setup an MRP profile to populate many of the required fields in the MRP 1 - 4 views.

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

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

b) Enter Mechanical Engineering as Industry Sector and Finished Goodsas Material Type

c) From the menu, choose Defaults→ Industry Sector.

d) Enter Mechanical Engineering, and select Hide Industry Sectoron Initial Screen.

e) Choose Continue .

2. Your recent position will only have you creating materials for a certainsection of the company. Therefore, set your user's default for theorganizational values Plant 1000, Sales Organization 1000 and DistributionChannel 10, and only display organizational levels on request.


b) From the system menu, select Defaults→Organizational levels.

c) Enter the following data:

Org Levels Copy To: Copy From:Plant 1000 1000

Sales Org 1000 1000

DistributionChannel

10 10

d) Select Org Level profiles only on Request, then choose Continue .



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3. Your recent position will only have you creating materials for a certainbusiness areas within the company. Therefore, set your user's default for thematerial master views for which you are responsible for creating. Set BasicData 1, MRP 1 - 4, Work Scheduling, Accounting 1, and Costing, to alwaysbe selected and select Create views selected so if you use any materials astemplates, you will not have to look at all views to create the material.


b) From the system menu, choose Defaults→View.

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

d) Choose Continue .

4. Create an MRP profile for rapid and secure maintenance of MRP data fromthe material record.

Create an MRP profile, SF##, with the description Semi Finished Group## for use in creating material masters with the material type Semi-FinishedProduct. Use the parameters in the following table for this exercise.

Note: Solution steps will appear after the table in the Solutionssection.

Data of MRP profile SF##Field Name Maintenance

StrategyDefault Value

MRP Type Fixedvalue

PD

MRP controller Default 0##

ABC Indicator Fixedvalue

A = important material

In-house productiontime

Default 5 days

Scheduling marginkey

Default 002

Lot Size (MaterialsPlanning)

Fixedvalue

EX = exact

Purchasing group Default 000



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Field Name MaintenanceStrategy

Default Value

Planning time fence Default 10 days

Component scrap in%

Default 1 %

Indicator:Backflush

Fixedvalue

2 = work center decides

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

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

c) When complete, select Save .

Task 2: Creating Material MastersAs a design engineer, you will be required to create material masters every day.You will use the defaults created in the previous task to speed up the process. Inthis section, you will be required to create five material masters. This will includetwo finished products and three semi-finished products.

1. Your supervisor has given you the specs on a new pump that has just comeout of research and development. She has asked you to enter the materialmaster into the system so that one of your colleagues can begin building thebill of material. No material currently has the same attributes, so you willcreate the new material with no template data. Use the following data tosupport the creation of the new finished production: T-F## (Rotary PumpGR##) at plant 1000.


Entry Screen DataMaterial Number T-F##


Basic Data 1Material Description Rotary Pump GR ##




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MRP 1MRP Type PD

MRP controller 0##

Lot Size EX - Lot for Lot

MRP 2In house Production 1

Scheduling margin key 001

MRP 3Strategy Group 10

Accounting 1Valuation Class 7920 - finished product

Price Control S-Standard Price


b) Enter the information as described in the table above. Use the ENTERkey to move to the next tab.

c) At the Costing 1 view, select Save or answer Yes to the questionto save your data.

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

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

b) Enter the material number T-B## and material type for Semi-Finishedgoods. Enter T-B1## as the copy from material.

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

d) Choose Save .



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

Answer: Take a look at all the selected views or choose Defaults �> Views .Select Create Views Selected.

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


b) Enter the material number T-Z## using reference material 102�100.

c) Select Organizational levels, and enter yourMRP Profile SF## ChooseContinue .

d) A warning will appear that the profile was copied from referencematerial. Be sure to click the New Entry button and enter your profileSF## once again before continuing.

e) In the Basic Data 1 view, change the description to GR## ALTCasing.

f) Before saving, review your MRP 1- 4 views to see if your profile hashad any affect.

g) Choose Save .

5. Your supervisor has given you the specs on a new centrifugal pump that hasjust come out of research and development. She has asked you enter thebasic data information of the new pump. The balance of the views will beentered at a later date. No material currently has the same attributes, so youwill create the new material with no template data. Use the following datato support the creation of the new finished product: T-F77## (CentrifugalPump GR##) at plant 1000.


Entry Screen DataMaterial Number T-F77##




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Basic Data 1 Datamaterial Description Centrifical Pump GR ##



b) Enter your material number and material type and select Views. ChooseDeselect all , then select Basic Data 1, and choose .

c) After entering in the data in the Basic Data 1 view, choose Save oranswer Yes to the question to save your data.

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


b) Enter the material number T-G## and material type �Semi Finished�using reference material 100-120.

c) Use the ENTER key to move through the views.

d) On theMRP 2 view, set the Co-product indicator, and continue pressingthe ENTER key.

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

f) Choose Save .


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Lesson Summary

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

benefit your business


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Lesson: Classification of the Material Master

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


� Describe how the material master can use classification to includecompany-specific fields

� Describe how classification can be used for batch management of inventory� Describe how classification can be used for variant configuration

Business ExampleAs the project lead for implementing material master files, you have severalrequirements regarding how to add custom fields to the material master. In thislesson you will learn the basic concept of how classification can be used tosupport material classification, Batch/Lot management, and variant configuration(features and options).

Use of Material ClassificationDuring the evaluation of your product data management process, your companymay realize that it needs custom fields to provide the organization with moreinformation on master data or transactional data. Without having to modify thedelivered SAP tables, companies can use the classification system to add fieldsto the material master for information purposes, or to provide more informationabout existing inventory.


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PLM114 Lesson: Classification of the Material Master

Figure 29: Classification of Master Data

Functions of the classification are:

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

To fulfill these objectives, you need to organize your data efficiently.

The SAP classification system is a tool for organizing your data that goes farbeyond match codes and systematically-structured number assignment.

Setup of ClassificationSAP ERP classification consists of the following components:

� Characteristic maintenance� Class types� Class maintenance� Classification (assignments)� Object search

Note: Course PLM130 contains more information on the SAPclassification system.


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Figure 30: Classification Functions

Classification can be used to describe or group objects together that have somelikeness, but also differences. An object is a classifiable unit (such as a material,vendor, or work center).

A characteristic describes specifications of an object, such as length, width,weight, color. Essentially, they are user-defined fields, which are defined asmaster data. Each characteristics must have a data type (numeric, characteristic,date, and so on). Companies define the length of the field, a template, and limitsor ranges to what values can be used. The same characteristic can be used manydifferent times for different purposes.

A class type describes a group of objects that have common or similarspecifications. When creating a class, a user must specify a class type. Class typescontrol how the classification can be used for various objects. The followingclasses can be used in conjunction with the material master:

� 001 - Material Class� 023 - Batch Management� 200 - Material (configurable)� 300 - Material (variant configuration)

A class can contain one or more characteristics. Within the class, companiescan further restrict the characteristic values. A class will then be attached to thematerial master to specify the custom fields that were needed.

A characteristic value represents the specification of a particular attribute, forexample, 10 cm, DIN 931, cast iron.


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Follow these steps to maintain classes:

1. Define characteristics and allowed characteristic values.2. Maintain the class, including assigning characteristics.3. Maintain the objects (for example, materials), including assigning them to

one or more classes and assigning values to them.4. Search for objects.

Figure 31: Characteristic Value Assignment

You can use characteristic values in various ways when using classification todetermine a material number.

For instance you can:

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

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


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Figure 32: Finding a Material

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

Use of Batch ClassificationSome industry sectors, in particular in the process industries, need to work with thehomogeneous subsets of a material or a product, which means, batches along theirentire supply chain. Batch management is integrated with all the applications ofthe SAP ERP and supports the management and processing of the batches and lotsin all the business processes of a company.

In particular, batch management is used in Supply Chain Management. A batchcan be followed through the whole supply chain, from the entry of the rawmaterials through the production of the finished product, and all the way to thesales and delivery to the customer.

To assign a batch to a material at the various points in the supply chain, you createa batch master record. For example, if the subset of a material that is subject tobatch management requirement leaves a production process (process order) withcertain specifications, it is posted to the stock with a batch number and can then beclearly identified.

A batch master record is identified by an alphanumeric batch number. You canselect the level at which you want the batch number to be unique in accordancewith the structure of your plant, company, and operational requirements.


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

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

Figure 33: Materials and Batches

In SAP ERP, batch master records depend on the corresponding material masterrecords. Batches are created for a material. The batch object contains the keyfields: Material, Batch, and Plant. The Plant field is relevant only if the plantlevel is used as the batch level.

Normally, the data of a material master record is valid for all the batches assignedto it. In contrast, a batch master record contains the data that uniquely identifiesa batch and characterizes it as a non-reproducible unit. You can further describebatch properties by classifying them in a class of the class type, 023 Batch.

If a material is to be produced in batches and is subject to inventory management,you must set the Batch Management indicator in the material master viewsPurchasing, Work Scheduling, or Warehouse Management.

Use of Variant Configuration in the Material MasterIn some industries, it makes sense to allow customers to request a product withmany options that suit their exact needs. However, if the number of options islarge, and no two products are likely to be exactly the same, companies couldend up with more master data than is feasible to manage. A personal computer(PC), for example, may have different hard drive options, processors, or graphics


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and sound options. This PC, therefore, has a large number of variants. Like thePC scenario, your company may have a situation in which it manufactures orsells products of which some exist in many variations. In order to reduce yourworkload and storage costs, and to enable you to maintain every possible endproduct variant, you choose to use the SAP ERP solution for variant configuration.

Figure 34: Configurable Personal Computer

Many steps are necessary to build up the master data for a configurable material.First, you must use the SAP classification system to describe the productcharacteristics. You allocate the characteristics to a class used for variantconfiguration. You then maintain object dependencies for characteristics andcharacteristic values so that only allowed values can be chosen. These objectdependencies are rules which define which components are compatible with others.

You must also maintain the necessary settings for the configurable material in thematerial master. You create a configuration profile by specifying the configurationparameters and allocating the material to the class with the characteristics thatdescribe it. The components and operations for a material are specified in a superBOM and a super task list.

You maintain object dependencies for the BOM components and task listoperations that can only be selected for particular variants. Before you use variantconfiguration productively, you should simulate the configuration. This allowsyou to check whether all the data has been correctly maintained.

Products with variants often have dependencies between the individualcharacteristics in which, not all combinations of characteristics are allowed. In thecase of the pump, for example, a rotary pump with manual and electric drive may


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be available, but a piston pump may only be available with an electric drive. Theterm configurable product is used to denote a product that can be manufactured inseveral variants. It comprises all the possible characteristics of the product, andis therefore not representative of any single product.

In the case of products that exist in many variants, the Super BOM contains all theparts that might be required to manufacture the configurable material. The partsactually required can be determined from the object dependencies.

Likewise, the Super Routing contains all the operations that could be neededto manufacture the configurable material. The operations and production toolsand resources that are actually needed for manufacture can be determined fromthe object dependencies.

A special product structure is dynamically generated for a configurable materialduring sales order processing.


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Exercise 2: Material Classification

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

Business ExampleAs a product design engineer, you are responsible for ensuring that materialmasters have all the necessary information for the user community to processdaily business transactions. As your business begins to grow you find that you arecreating new part numbers every day and the user community is finding it difficultto search and find the necessary material numbers. In order to make their jobsmore efficient you have decided to begin classifying your material masters.

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

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

2. List the characteristics that belong to class 100

Characteristic Description

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



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Values

Task 2: Classifying Material MastersIn a previous task, you reviewed existing classification data to support addingcustom fields to the material master. Classify your new pump and see if you canfind it and others like it using the Find function and classification.

1. Update your material master for pumpT-F## by adding the classificationview and by assigning it to material class 100 - Pumps. Give it the followingdata:

Note: If you have not already done so, you will have to create theclassification view.

Characteristics ValuePump Lift 10 m

Pump Capacity 20 m3

Turning Speed 1000

Material cast iron (GRAUGUSS)

Usage Industrial(INDUSTRIE)

2. Search for a reference material by using classification in the following way:


Pump Capacity 20 m3

Turning Speed 1000


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Solution 2: Material ClassificationTask 1: Review Classification DataAs a product engineer, your companies business been to growing steadily overthe past year. You find yourself creating new part numbers every day and theuser community is finding it difficult to search and find the necessary materialnumbers. In order to make their jobs more efficient you have decided to beginclassifying your material masters. Review existing classification data to see if itwill work with your new pumps

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

a) Use the menu path Cross Application Components→ ClassificationSystem→ Master Data→ Classes (CL02).

b) Enter class 100 and class type 001 and choose Display .

2. List the characteristics that belong to class 100

Characteristic DescriptionC001 Pump LiftC002 Pump CapacityC003 Turning SpeedC004 MaterialC005 Usage

3. What values, if any, have be assigned to C001 - Pump lift?

Hint: Select the characteristic and select Display Values

Values10 m20 m30 m40 m

Your instructor may have added another characteristic during a classdemonstration via the material master.



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Task 2: Classifying Material MastersIn a previous task, you reviewed existing classification data to support addingcustom fields to the material master. Classify your new pump and see if you canfind it and others like it using the Find function and classification.

1. Update your material master for pumpT-F## by adding the classificationview and by assigning it to material class 100 - Pumps. Give it the followingdata:

Note: If you have not already done so, you will have to create theclassification view.


Pump Capacity 20 m3

Turning Speed 1000

Material cast iron (GRAUGUSS)

Usage Industrial(INDUSTRIE)

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

b) Enter material T-F## and select Views. Select Classification andchoose Continue .

c) Enter class 100 and press Enter.

Note: If a class type other than 001 appears in your materialmaster, choose Extras→ Change class type and enter classtype 001.

d) Enter the data from the above table; make sure to choose afterselecting a value and choose Save .

2. Search for a reference material by using classification in the following way:



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Pump Capacity 20 m3

Turning Speed 1000

a) Choose Cross Application→ Classification System→ Find→ FindObjects in Class.

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

c) Enter your pump height, pump capacity and turning speed, and chooseFind in Initial Class.


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Lesson Summary

You should now be able to:� Describe how the material master can use classification to include

company-specific fields� Describe how classification can be used for batch management of inventory� Describe how classification can be used for variant configuration


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PLM114 Lesson: Managing the Material Master

Lesson: Managing the Material Master

Lesson OverviewIn this lesson you will learn how to manage changes to existing material mastersusing various functions in SAP ERP


� Describe different ways to update or change the material master� Demonstrate the mass maintenance features of the material master� Describe how the material master can be updated using the request processes

with interactive forms for materials management� Describe the archiving and deletion process for the material master

Business ExampleAs the project lead for implementing material master files, you are responsiblefor the process to manage changes to the material master. You must begin todevelop some standard business processes to work with updating and maintainingmaterial masters.

Overview of Updating the Material MasterOver the course of time, attributes of the material master will change. Thereforeyou must be aware of the different change functions of the material master in orderto better incorporate your business processes with those of SAP ERP.

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

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

Extending the Material MasterWhen material masters are created, all of the information may not have beenavailable. This may result in some views not getting created.


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Figure 35: Extending the Material Master

By using the transaction Extend Material View(s), you can extend the materialmaster record by adding more views. This transaction can be found underLogistics→ Production→ Master Data→ Material Master→ Other→ ExtendMaterial View(s) (MM50).

The following questions should be answered:

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

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

Department Maintenance statusWork scheduling AAccounting BClassification CMRP DPurchasing EProduction resources/tools FCosting GBasic data K


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See maintenance status in transaction MM50, Extend Material View(s).

Hint: If additional views are added to the existing master record, you canalso use the Create material function.

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

� Because the material type influences internal processing, the system checkswhich changes are allowed.

� You can change the material type without restriction if no stocks,reservations, or purchasing documents exist.

� If stock, reservations, or purchasing documents exist, the material type canbe changed if:

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

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

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

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

Material StatusThroughout the lifecycle of a product, changes will be both major and minorin nature. When major changes occur, a business will need ways of warningor preventing certain business activities from occurring. By configuration andusing the material status, companies can restrict or warn other business areas ofchanges that will be impacting their areas.


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Figure 36: Material Status

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

� You can flag the material for deletion� You can use the material status to lock the material for certain business

processes in materials management and production planning,

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

� Choose Extras→ Status information in any screen.

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

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


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You can define the material status for all plants (basic data view) or separately foreach plant (plant view).

Hint: The more restrictive status has priority (regardless of whether it isthe cross-plant status or the plant-specific status).

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

Figure 37: Mass Maintenance of Material Master


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Mass maintenance enables many objects to be changed at the same time. Onlyusers with the relevant experience should therefore use this tool. To performmass maintenance, follow these steps:

1. Start the transaction for mass maintenance, MM17. If you have alreadydefined a variant, you can enter this here.

2. Select the tables for which you would like to see the data.3. Select the fields you want to change on the relevant tab page, and click

Execute.4. Enter the desired selection criteria. You can select other fields by clicking

Select Fields.

The system selects the data records. Depending on how many data recordsyou have selected, the system may ask whether you would like to continueworking in the dialog or whether you would like to perform the changes inthe background. If you choose the second option, a workflow will inform youlater that the changes you made were carried out. If you continue working inthe dialog, the system will display the data records you have selected.

5. Enter the new value in the corresponding column, select the column header(for example, short text) and the data records you wish to change and chooseChange Field Values. You have the following options:

� Change only those fields that have a definite current value� Display previous value� Test changes

6. Save the data.

The system will perform a consistency check for the data you changed.Changes that lead to data discrepancies are not executed and a note is enteredin the log.

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


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Figure 38: Deleting a Material

All records flagged for deletion are deleted during a reorganization run providedthey are no longer being used, for example, as a BOM header.

Deletion is carried out in these steps:

1. Material master is flagged for deletion.2. Material master is selected for a reorganization run.3. Reorganization run is executed.

Hint: During the reorganization run, the system checks whether materialmay be deleted and whether material may be archived.


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Figure 39: Archiving a Material

You can also archive material master records. The data is stored in a sequential file(archive file). Archived data can be deleted from the database using the deletionprogram or reorganization. Archived material master records can be displayed,but they cannot be retrieved.

Using transaction MM71, Archive/Delete, you can see which other objects need tobe deleted prior to a material master. By clicking the Network Graphic icon ,you can see which objects needed to be deleted prior to deleting and archivingthe material master.

Archiving and reorganization are handled in greater detail in the administrationcourses.


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Exercise 3: Managing Material Masters

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

Business ExampleAs the process design engineer manager, you are responsible for entire materialmaster management process. To do your job efficiently, you must betterunderstand how the different transactions work in updating the material master inorder for you to develop a business process. Therefore you will execute severalupdates to existing material masters in order to better understand the functionalityin SAP ERP.

Task 1: Updating the Material MasterAs the business process owner for the material master life cycle, you arereviewing the different methods to maintain the material master. The differentmethods will include manual changes, extending the material master, and masschanges. Execute the following task and determine how you will incorporate thetransactions into your business process.

1. Your new pump T-F77## has slightly different dimensions from the otherpumps you work on. This will cause the alternative units of measure to differfrom the other pumps. Change the alternative units of measure so that 4pumps go into a carton, and 8 cartons per pallet.

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

Extend the finished product T-F77## to plant 1000 and create the MRP 1 - 4views (D) and Work Scheduling view (A), using the Extend Material View(s)transaction. Include the following data:

Note: Maintain work scheduling first, save your entries, and thenmaintain the MRP views. Press Enter through any necessarymessages.



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Field Name User EntryProduction Scheduler 0##

Purchasing Group 0##

MRP Type PD

MRP Controller 0##

Lot Size EX

In House Production 2 days

Sched. Margin Key 001

Strategy Group 40

Selection Method 2 - Selection byProduction Version

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

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

1. Your business creates new replacement parts every day. To minimize risk,your company wants to be more expeditious in obsoleting materials. Totest this process, you create a material through which you can simulate theprocess of obsoleting the material. Create the following material masterrecord by copying from a reference material:

A finished product with material number T-D## (## = group number) inplant 1000, copied from material T-F1## using your default views. Changethe description to GR## Pump Obsolete.

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



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3. To make sure the deletion flag works, try to perform a goods issue usingtransaction code MB1C for your material T-D## at plant 1000, storagelocation 0002 using movement type 501.

Caution: Do not save your entries.

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

5. After applying the obsolete material status, try to receive another goodsreceipt to see if this will prevent possible mishaps with obsolete materials.Use transaction code MB1C for your material T-D## at plant 1000, storagelocation 0002 using movement type 501.



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Solution 3: Managing Material MastersTask 1: Updating the Material MasterAs the business process owner for the material master life cycle, you arereviewing the different methods to maintain the material master. The differentmethods will include manual changes, extending the material master, and masschanges. Execute the following task and determine how you will incorporate thetransactions into your business process.

1. Your new pump T-F77## has slightly different dimensions from the otherpumps you work on. This will cause the alternative units of measure to differfrom the other pumps. Change the alternative units of measure so that 4pumps go into a carton, and 8 cartons per pallet.

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

b) Enter your material, select Organization Levels and choose BasicData 1.

c) From the Basic Data 1 screen, choose Go to Additional Data, andselect the Units of Measure view.

d) Add the data mentioned above:

4 pc = 1 carton

32 pc = 1 pallet

Note: All units of measure are converted from the base unitof measure.

e) Save

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

Extend the finished product T-F77## to plant 1000 and create the MRP 1 - 4views (D) and Work Scheduling view (A), using the Extend Material View(s)transaction. Include the following data:

Note: Maintain work scheduling first, save your entries, and thenmaintain the MRP views. Press Enter through any necessarymessages.



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Field Name User EntryProduction Scheduler 0##

Purchasing Group 0##

MRP Type PD

MRP Controller 0##

Lot Size EX

In House Production 2 days

Sched. Margin Key 001

Strategy Group 40

Selection Method 2 - Selection byProduction Version

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

b) Select maintenance status D - MRP and A - Work scheduling, andenter your material T-F77##, and then choose Execute .

c) Select the line for T-F77## and chooseMaintain Materials.

d) Press Enter through the error message and enter plant 1000.

e) Enter the data in the above chart and choose Save when finished.

3. Although you are considering having each department maintain theirown views, you are still in charge of maintaining the entire materialmaster. The Production manager for you pumps has just asked that you



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update the material master with the correct production scheduler. Usingmass maintenance update all your pumps T-F*## in plant 1000, with theproduction scheduler 0##.

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

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

c) In the Fields tab, choose Find , enter Prod, and choose Continue. Continue searching using the search function until the ProductionScheduler line appears.

d) Select the line containing Production scheduler: MARC-FEVOR andchoose Execute .

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

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

g) Choose Carry out Mass Change .

h) Choose Save , and Continue through any warnings.

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

1. Your business creates new replacement parts every day. To minimize risk,your company wants to be more expeditious in obsoleting materials. Totest this process, you create a material through which you can simulate theprocess of obsoleting the material. Create the following material masterrecord by copying from a reference material:

A finished product with material number T-D## (## = group number) inplant 1000, copied from material T-F1## using your default views. Changethe description to GR## Pump Obsolete.


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

c) In the Basic Data 1 view, change the description to GR## PumpObsolete.

d) Choose Save .



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

a) Use menu path Logistics→ Production→ Master Data→ MaterialMaster→ Material→ Flag for Deletion→ Immediately or transactioncode MM06.

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

c) Select the above material.

d) Choose Save .

3. To make sure the deletion flag works, try to perform a goods issue usingtransaction code MB1C for your material T-D## at plant 1000, storagelocation 0002 using movement type 501.


a) Enter transaction code MB1C or choose Logistics→ MaterialsManagement→ Inventory Management→ Goods Movement→ GoodsReceipt→ Other.

b) Enter movement type 501, plant 1000, storage location 0002 andpress Enter.

c) Enter your material T-D## and a quantity of 1 pc, and press Enter.

Note: This should result in a warning that the deletionindicator is set.

d) Do not save your entries.

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

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

b) Select the Basic Data 1 view.

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

d) Choose Save .



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5. After applying the obsolete material status, try to receive another goodsreceipt to see if this will prevent possible mishaps with obsolete materials.Use transaction code MB1C for your material T-D## at plant 1000, storagelocation 0002 using movement type 501.


a) Enter transaction code MB1C or choose Logistics→ MaterialsManagement→ Inventory Management→ Goods Movement→ GoodsReceipt→ Other.

b) Enter movement type 501, plant 1000, storage location 0002 andpress Enter

c) Enter your material T-D## and a quantity of 1 pc, and press Enter

Note: This should result in an error message that states thatthe material has a status of �Obsolete Materials in plant 1000.�

d) Do not save your entries.


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Lesson Summary

You should now be able to:� Describe different ways to update or change the material master� Demonstrate the mass maintenance features of the material master� Describe how the material master can be updated using the request processes

with interactive forms for materials management� Describe the archiving and deletion process for the material master


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Lesson: Configuration of the Material Master

Lesson OverviewIn this lesson you will learn about the customized material master record as wellas other check tables. The following aspects of the customized material masterrecord are explained:

� Screen sequence� Logical screens� Subscreens� Influencing factors


� Describe the process of influencing the field characteristics of the materialmaster

� Describe Process of configuring the screen layout of the material master� Set up a customized material master in Customizing� Test the settings by creating a material master

Business ExampleAs the project lead for implement material master files, you must be aware of thestructural design of the object in SAP ECC. One of the business requirementsyour company has is to make certain fields required input before save a materialmaster. In addition users have commented on the screen the layout of the standSAP material master. In this lesson you will learn how to make fields in thematerial master required, and acquire a basic understanding of customizing thelayout of the material master.


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PLM114 Lesson: Configuration of the Material Master

Configuration Sequence for Material Master Records

Figure 40: Configuration Sequence for Material Master Records

The abbreviations in the graphic have the following meanings:

� M = Required activity (required)� O = Optional activity (optional)� D = Default available for activity (default)

Control Using Material TypeYou specify a material type for each material. The material type is part of thegeneral data of a material.

By specifying which views can be used for a material type, you determine whichuser departments can maintain a material with this material type.


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Figure 41: Control Using Material Type

You can control the type of inventory management (quantity and/or value) for amaterial type depending on the plant.

Price control can be defined as a default value or as a fixed value.

Material stock accounts and consumption accounts are assigned by using valuationclasses.

You can determine inconsistencies in valuation areas using the Customizing forthe material type.

The material type is an influencing factor for the field selection and the customizedmaterial master.

You can control access protection in more detail by using the authorization group.

Hint: Material types that are maintained by customers can also beassigned to the transaction codes delivered by SAP. For example, go totransaction code MMR1 Material→ Create specifically→ Raw materialin Customizing step Assign material types to special create transactionsand replace material type ROH with customer-defined material ZROH.The advantage of this is that the material type does not have to be enteredwhen the material is created.

Material StatusThe material status allows you to control the use of a material for businesspurposes.


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The material status is defined depending on material, client, and plant.

You can limit the usability of a material in different ways:

� The material can be flagged for deletion.� The material can be locked for certain business transactions by the material

status for material management/production planning and control

Figure 42: Material Status

You can display whether a material is subject to restrictions, and what theserestrictions are with the status information function. You can call this functionwhen you create, display, or change a material master record. Proceed as follows:Choose Extras - Status information from any screen.

You can define the material status for all plants (basic data view), or separately foreach plant (plant view).

Hint: The more restrictive status always wins out (independent of storagelocation or plant).


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Field SelectionFollow these steps to set field selection:

1. Determine the field selection option (hide, and so on).2. Determine the control string (material type, and so on).3. Determine the field selection group.4. Change the control indicator for the field selection group in the corresponding

control string.5. Test the change.

Figure 43: Field Selection Procedure

You can find out the table name of a field by using the technical information inthe F1 help.

In Customizing, you can use the table name to help you find the appropriatefield selection group.


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Figure 44: Field Selection - Field Selection Group

One or more material master fields are assigned to a field selection group.

The field selection option applies to all the fields in the field selection group (forexample, all the fields are required fields).

Hint: Always check first which fields have been assigned to a fieldselection group. Do not make changes without consulting the affecteddepartment.

Figure 45: Field Selection - Influencing Factor


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A separate control string exists for each of these influencing factors.

Each position in a control string of this kind applies to a specific field selectiongroup. The field option applies to the entire field selection group and all themaster data contained in it.

You generally use a reference key to specify which control list is valid for aninfluencing factor.

You can maintain the reference key for the material type, plant, and industry sectorin the settings menu.

Each position in a control string defines the field selection for a group of materialmaster record fields. In the settings menu, you can determine to which group theindividual fields are assigned.

Figure 46: Field Selection - Link Rules

Field selection in a material master transaction is generally determined by severalcontrol strings. The entries of all the control strings for the relevant transaction arelinked to one another.

The link rules shown above determine which fields are selected for each group ofmaterial master fields. In order of priority, the signs mean:

- Hide* Display+ Required entry. Optional entry


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Customizing the Material MasterYou can structure the material master according to your company's requirements:

� You can remove screens, which are not required, from the screen sequence.� You can create your own screens, by adding or deleting screen modules.� You can influence individual fields in the screen modules.

Figure 47: Customized Material Master (1)

Customized material master records support efficient data maintenance by lettingyou create entry screens that suit your company's data requirements. The materialmaster record is a set of logical screens which appear in a specific sequence ifmore than one view is selected. This is referred to as a screen sequence.

Each logical screen consists of several related field groups. In ECC these arereferred to as subscreens. The fields assigned to each screen module cannot bechanged in Customizing.

In Customizing for the material master, you can:

� Create and maintain screen sequences� Maintain logical screens� Maintain the order of logical screens in a screen sequence� Determine which subscreens appear on which logical screens� Assign influencing factors for field selection to a screen sequence� Assign a user or user group to a screen sequence� Preset the default organization level, default industry sector, and logical

screens for a user or group of users

The views of the material master record correspond to the logical screens inCustomizing. The logical screen is the visible data screen.


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There are main screens (maximum of 29), additional screens (maximum of 15)and other screens (non-configurable, for example, initial screens).

The additional screens are assigned to the main screen using the PB## functioncodes (this corresponds to the name of the pushbutton in the Screen Painter).

The secondary screens can be added to the additional data screens with automaticnumbering (maximum of 15 additional screens including secondary screens).

Figure 48: Screen Sequence

A screen sequence consists of logical screens (views) and secondary screens.

The sequence of the screens can be specified for each screen sequence.

You can define a screen sequence to suit your requirements.

Figure 49: Subscreens


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A logical screen (view) consists of several screen modules. It consists of asubscreen container where you can enter several subscreens (maximum of 6).

Standard screen modules (SAPLMGDI) have exactly one frame that can containup to 10 lines and they have exactly 83 columns.

You are free to choose the sequence of the screen modules.

You can vary the number of subscreens for each logical screen.

Subscreens from different logical screens can be grouped together on one screen.The maintenance status of the screen module fields must be the same as themaintenance status of the logical screen. You may have to extend the status of thelogical screen in Customizing.

Changes to a logical screen are saved in the screen sequence that is changed. Thismeans that if you change the structure of MRP 1 in sequence 99, this change isonly effective in sequence 99.

Figure 50: Topic Summary: Customized Material Master

When creating your own logical screens we recommend that you use the standardsubscreens that are already available.

You will need your own subscreens if different field groups or new fields arerequired.

To create your own subscreens, copy standard program SAPLMGD1 to its ownfunction group (for instructions, see the IMG). Then create the required subscreenin the new function group.

Append structures have been defined in DDIC for including your own fields.


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You can only include fields from user-specific tables and user-specific subscreencontainers in program SAPLMGMM by using modifications.

Before you configure your own material master record dialogs, be sure to readthe IMG.


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Setting Up Screen Sequences

1. Set up a customized screen sequence Y# (where # equals 1 to U for groups01 to 30) for material master maintenance.

Use screen sequence 21, Std ind.(short) tab pages as a template for yourscreen sequence Y#, screen sequence GR ##.

2. From the SAP Easy Access screen, choose Tools→ Customizing→ IMG→ Edit project (transaction SPRO).

Choose Display SAP Reference IMG (= F5).

Choose Logistics general→Material master→Configuring material masterrecords→ Define structure of the data screens for each screen sequence.

3. In the dialog structure for maintaining screen sequences, data screens, andsubscreens, copy screen sequence 21 with all its dependent entries to yournew screen sequence Y#. Save the screen sequence.

In the Screen Sequences view, select 21.

Choose Copy As (= F6).

Y# screen sequence group ##

Choose Enter.

Wait! Approximately 3000 dependent objects are copied.

Choose Save.

4. Select your new screen sequence Y# and double-click on Data screens to goto the dialog structure. Select the data screen Basic data 2 (Screen: 08 ) anddouble-click on subscreens to go to the subscreens. Select module 2010 andchoose Delete (Shift+F2). Return to the data screen view.

5. The data screen 29 (MRP 4) should be adjusted. Simulate the screen first,and then delete all subscreens except:

1005 Material number2502 Control repetitive manufacturing2504 Discontinuation control.

You should use the subscreen procurement (2484) from the data screen 27(material requirements planning 2). Simulate your changes.

Select data screenMRP 4 (screen 29) and display the subscreens. Displaythe subscreens by clicking Data screen view. (Leave view using Exit.)

Select and delete all subscreens except1005, 2502, and 2504.



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Overwrite the first subscreen 0001 ( = sequence number 4) with that ofprocurement 2484 from screen 27.

Simulate the changed screen: Data screen view.

Save your changes.

6. Delete data screen 27 (MRP 2) from your screen sequence.

Go back to the Data screens view again, select theMRP 2 (screen 27) screenand delete it with all its dependent entries.

Approximately 92 dependent objects are deleted.

Choose Save.

7. Change your screen sequence ## so that the data screens appear in thefollowing sequence:

1. Screen Basic data2. Screen MRP 43. Screen Work scheduling4. Screen Storage location stock5. Screen Classification

The rest of the sequence following these data screens should remainunchanged.

Under Maintain Order of Main and Additional Screens, select your screensequence number and click the Details icon or double-click on the newscreen sequence.

Change the order according to the task.

MRP 4 140 �> 11Work scheduling 160 �> 12Storage location stock 280 �> 13Classification 30 �> 14

Choose Sort Main Screens (renumbering) and save the new sequence.

8. The screen sequence should be effective for your user. Define a screenreference for your user and determine a new list of influencing factors.



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In Screen sequences for users / material types / transactions /assign industrysectors, display the step Screen reference user. Maintain a new entry.Use the user name that you used to log on to the system and assign anabbreviation to it. For example, Y# (the same abbreviation as the new screensequence). Choose Save.

Under Controlling screen sequence, create a new string (New entries) orcopy the existing control string with the screen sequence 21 as a template,and enter the following values:

SRef: trans. 01ScrRef.User The user reference you created (F4

help if saved previously)ScrRef. matl type *ScrRef. industry *Scr.sq The screen sequence number you

created (input help)

Save your changes.

9. Check your settings by displaying material master T-F1##.

Check your settings as described in the exercise.

General Check Tables for the Material Master Record

Figure 51: Other Check Tables for the Material Master Record


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The material master contains a series of fields that are checked against othertables. These tables must be set up before you create material master records.

Hint: In addition to the check tables listed above, there are also checktables for which no hard check is performed. In other words you neednot necessarily make an entry in Customizing. Here you can make entriesthat were not made available previously. However, these entries do notupdate the Customizing table: For example basic material in basic data 2.


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Exercise 4: Material Types, Field Controland Material Status

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create a new material type� Set up a new field selection for your new material type and a new material

status

Business ExampleA new material type is needed in plant 1000. Because the old material numberfrom the legacy system is very important, it is to be turned into a required entry inSAP ECC. A new material status should only allow the maintenance of BOMswith a warning message.

Task 1:Add a new material typeMA## (## = group number).

1. As a template, use the material type for the finished product FERT. Changethe description of a new material type in group ##. Save the newly createdmaterial type before processing further.

Account assignment is to be according to account category reference 0009,the same as for material type FERT.

2. Note the following specifications for the new material type:

- External and internal purchase orders are allowed.

- Externally assigned material numbers should not be checked against anumber range.

- Cost estimate with quantity structure (BOM, routing) is allowed.

For materials of this material type, the following views are allowed to bemaintained: Work scheduling, accounting, classification, MRP, purchasing,costing, basic data, storage, plant stocks, and storage location stocks.

In all plants (valuation areas) the quantities and values for materials of thismaterial type should be updated.

The valuation of all materials of this material type should be binding (thatmeans not changeable) according to the valuation procedure movingaverage price.



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Task 2:Check the number assignment for materials of your material type.

1. Make sure that the number assignment for materials of your material typeMA## uses the same number range group as for the template material typeFERT.

Task 3:Material typeMA## is used for the finished products that are copied from anexternal system. The following material fields are to be required fields for materialtype MA##:

Material description Field name completeOld material number (MARA-BISMT)Material status (cross-plant) (MARA-MSTAE)

You can see the data for the individual fields that you want to change by usingthe field help (F1 or Help icon) and choosing the Technical Information button orthe Technical Information icon.

1. To which field selection group do these fields belong?

2. When you create a new material master record using the copy function,are the contents of the fields copied?

3. What other fields belong to these groups?

4. Copy the field selection reference Z## with reference FERT, and define thefields mentioned above as required fields at the same time.

5. Now assign the field selection reference Z## to your material typeMA##.

6. Test your setting by creating a material T-A## with material typeMA##(basic data views 1 and 2 only and work scheduling for plant 1000). Theold material number for this material is your choice. Use material status 02on valid-from date <today>.


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Solution 4: Material Types, Field Controland Material StatusTask 1:Add a new material typeMA## (## = group number).

1. As a template, use the material type for the finished product FERT. Changethe description of a new material type in group ##. Save the newly createdmaterial type before processing further.

Account assignment is to be according to account category reference 0009,the same as for material type FERT.

a) Creating a new material type:

From the SAP Easy Access screen, choose Tools→ Customizing→ IMG→ Edit project (SPRO).

Choose Display SAP Reference IMG (F5).

Choose Logistics general→ Material master→Basic settings→Material types→ Define attributes of material types.

Select material type FERT.

Click Copy (F6).

2. Note the following specifications for the new material type:

- External and internal purchase orders are allowed.

- Externally assigned material numbers should not be checked against anumber range.

- Cost estimate with quantity structure (BOM, routing) is allowed.

For materials of this material type, the following views are allowed to bemaintained: Work scheduling, accounting, classification, MRP, purchasing,costing, basic data, storage, plant stocks, and storage location stocks.

In all plants (valuation areas) the quantities and values for materials of thismaterial type should be updated.



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The valuation of all materials of this material type should be binding (thatmeans not changeable) according to the valuation procedure movingaverage price.

a) Check all points according to the task set, and change if necessary:

� Name� Description� Internal/external order = 2� User department (like FERT, but without forecast, QM, warehouse

management, and sales)� Quantity/value update: 1 flag each� Valuation: Price ctrl mandatory

Task 2:Check the number assignment for materials of your material type.

1. Make sure that the number assignment for materials of your material typeMA## uses the same number range group as for the template material typeFERT.

a) In Customizing, choose Logistics general→ Material master→ Basicsettings→ Material types→ Define number range for each materialtype.

Choose Change groups (F6).

Your material type should already be assigned to group 1 (the same asFERT). If not, select material typeMA##, select the group to whichmaterial type FERT belongs and choose Assign element / group (F5).

You may want to display the assigned number ranges here, too: chooseMaintain (Shift+F5).



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Task 3:Material typeMA## is used for the finished products that are copied from anexternal system. The following material fields are to be required fields for materialtype MA##:

Material description Field name completeOld material number (MARA-BISMT)Material status (cross-plant) (MARA-MSTAE)

You can see the data for the individual fields that you want to change by usingthe field help (F1 or Help icon) and choosing the Technical Information button orthe Technical Information icon.

1. To which field selection group do these fields belong?

a) Setting fields as required entry: First you determine the numbers of thefield selection groups. For this, choose Logistics general→ Materialmaster→ Field selection: Assign fields to field selection groups inCustomizing.

Field selection groups (search by field name)

MARA-BISMT: 11MARA-MSTAE: 155

2. When you create a new material master record using the copy function,are the contents of the fields copied?

a) The contents of the fields is copied on creation, because the referenceindicator (default field content) is set.

Select the field and click on Detail or double-click on the field names.

3. What other fields belong to these groups?

a) Display the field selection maintenance in field group maintenance.

Find these fields in the Field groups table:

MARA-BISMT: 11MARA-MSTAE: 155

Choose the Field selection maintenance icon (or correspondingpushbutton in the right-hand column).

There are no more fields for field selection group 11.

Group 155 includes the fieldMARA-MSTDE (date from which thecross-plant material status is valid).



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4. Copy the field selection reference Z## with reference FERT, and define thefields mentioned above as required fields at the same time.

a) In Customizing, use the menu path Logistics general→ Materialmaster→ Field Selection→Maintain Field Selection for Data Screensor click the Field sel. maint. button in the previous exercise.

b) Copy a field selection reference with the new name Z## and set it upso that the fields named above are displayed as required entries. Asa template, use the field selection reference for the finished productFERT.

Select the line FERT and copy it to Z## (choose Edit→ Copy as, orcorresponding pushbutton, or F6).

Name Z##Line 11 Required entryLine 155 Required entry

Enter and save.

5. Now assign the field selection reference Z## to your material typeMA##.

a) Assign the field selection reference Z## to the material typeMA##,while you assign the field selection Z## to the material type.

In Customizing, choose Logistics general→ Material master→ Basicsettings→ Material Types→ Define attributes of material types andthen Change.

The field reference is Z## instead of FERT.

6. Test your setting by creating a material T-A## with material typeMA##(basic data views 1 and 2 only and work scheduling for plant 1000). Theold material number for this material is your choice. Use material status 02on valid-from date <today>.

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


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Lesson Summary

You should now be able to:� Describe the process of influencing the field characteristics of the material



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Unit Summary PLM114

Unit SummaryYou should now be able to:� Describe the organizational layout of the material master� List the prerequisites to creating material masters� Use various methods to create material masters� Describe the request process with interactive forms and explain how it might

benefit your business� Describe how the material master can use classification to include

company-specific fields� Describe how classification can be used for batch management of inventory� Describe how classification can be used for variant configuration� Describe different ways to update or change the material master� Demonstrate the mass maintenance features of the material master� Describe how the material master can be updated using the request processes

with interactive forms for materials management� Describe the archiving and deletion process for the material master� Describe the process of influencing the field characteristics of the material



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PLM114 Test Your Knowledge

Test Your Knowledge

1. The classification system, all classes, characteristics, and characteristicvalues are predefined by SAP and delivered with the system and cannotbe changed by users.Determine whether this statement is true or false.□ True□ False

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

3. A batch is a unique homogeneous subset of a material, which is notreproducible.Determine whether this statement is true or false.□ True□ False

4. Variant configuration uses classification to select specific items on the billof material and the corresponding operation on the routing for products thathave many different options.Determine whether this statement is true or false.□ True□ False

5. A new material type can be created by simply clicking New Entries andentering the data.Determine whether this statement is true or false.□ True□ False


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Test Your Knowledge PLM114

6. Which of the following can be used to influence the screen sequence andattributes (required, visible, hidden) of the material master record.Choose the correct answer(s).□ A User ID□ B Material type□ C Plant□ D Industry□ E Transaction


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Answers

1. The classification system, all classes, characteristics, and characteristicvalues are predefined by SAP and delivered with the system and cannotbe changed by users.

Answer: False

The classification system is a user-defined way for companies to create theirown classes, characteristics, and characteristic values.

2. Only material master records can be classified using the classification system.

Answer: False

In addition to material master records, the classification system can be usedto classify routings, work centers, PRTs, and documents.

3. A batch is a unique homogeneous subset of a material, which is notreproducible.

Answer: True

Because each batch has unique characteristic values, it is a unique subset of amaterial that cannot be reproduced.

4. Variant configuration uses classification to select specific items on the billof material and the corresponding operation on the routing for products thathave many different options.

Answer: True

Variant configuration uses class type 300 and object dependencies in theBOM and routing to select specific items on the bill of material and thecorresponding operation on the routing for products that have many differentoptions.

5. A new material type can be created by simply clicking New Entries andentering the data.

Answer: False

A new material type can be created only by copying an existing materialtype and making changes. There are so many underlying dependencies ona material type that they must be copied to be sure all of the dependenciesare also copied.


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6. Which of the following can be used to influence the screen sequence andattributes (required, visible, hidden) of the material master record.

Answer: B, C, D, E

Material type, plant, industry, and transaction as well as procurementindicator can all be influencing factors in controlling the screen sequenceand field attributes of a material master record.


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Unit 4Bills of Material

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


� Describe the organizational layout of the bill of material� Demonstrate the validity process and changing an active bill of material� Demonstrate how engineering change management (ECM) affects the

validity of a bill of material� Describe the process of archiving and deleting a bill of material� Demonstrate the various bill of material reports that are available to

individuals� Demonstrate the comparative reporting tools for bills of material� Describe the configuration activities surrounding the BOM header� Describe the configuration activities surrounding the BOM items

Unit ContentsLesson: Overview of the Bill of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

Exercise 5: BOM Basics: Display ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143Lesson: Managing Bills of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

Exercise 6: Changing Bills of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161Lesson: BOM Reporting .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

Exercise 7: Multilevel BOM Reporting .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183Lesson: Configuration of the Bill of Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

Exercise 8: Bill of Material Configuration... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197


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Unit 4: Bills of Material PLM114

Lesson: Overview of the Bill of Material

Lesson OverviewThis lesson introduces the bill of material.


� Describe the organizational layout of the bill of material

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

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

Figure 52: Bill of Material Definition


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PLM114 Lesson: Overview of the Bill of Material

BOMs can be found in various forms wherever finished products or semifinishedproducts are produced from several component parts or materials.

Depending on the industry sector, they may be called:

� Recipe� List of ingredients

Figure 53: Terminology

AssemblyAn assembly is a set of components for a product that belong together forproduction purposes. The assembly may itself be used as a component inanother assembly.

Single-level BOMA single-level BOM is a set of all the components that represent one ormore assemblies.

Component, part, and item are all synonyms.


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Figure 54: BOM Integration

Data that is saved in BOMs forms a significant basis for various areas withinproduction planning.

Engineering design creates BOMs. You can create BOMs in ECC using acomputer-aided drawing (CAD) program and a CAD interface.

Material requirements planning (MRP) explodes BOMs in order to determineeconomical order quantities at a particular point in time.

� In work scheduling, BOMs form the basis for the planning of operationsand shop floor control.

� Production order management uses BOMs to plan the provision of parts.

The BOM is also used:

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

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


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Figure 55: BOM Categories

BOM categories define the connection to an object.

Material BOMs are used in SCM to represent the structure of products that aremanufactured.

Order BOMs are used to produce a product for a specific sales order.

A document structure can consist of several documents, for example, a program,technical drawings, paper documents, and photographs. You need document inforecords for these.

Equipment BOMs are used in plant maintenance to describe the structure ofa piece of equipment and to assign spare parts to the piece of equipment formaintenance purposes.

Functional location BOMs are used in plant maintenance to link equipment tospecific locations.


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Figure 56: BOM Usage

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

� The engineering BOM combines all components of the product from theengineering point of view and contains all technical data.

� The production BOM is set up from the manufacturing points of view. Forexample, process data is required for assembly.

The costing BOM is the basis for the automatic calculation of the material usagecosts of a product.

Of course, you can also work with just one BOM for all areas by using the itemstatus to cover all possible differences.

When creating BOMs with different usages for one material, the system saves

each BOM with a separate internal number for each usage.


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Figure 57: BOM Status

The BOM status controls BOM processing in different application areas. Whenyou configure your system in Customizing under Bill of Material→ DefineBOM status, you define the statuses for different indicators that allow or disallowBOM processing.

Examples:

BOM AA BOM with status 1 can be exploded in MRP and released for a plannedorder.

BOM BA BOM with status 2 cannot be exploded in MRP or released for a plannedorder.

When you configure your system in Customizing under Bill of Material, eachcompany defines which item statuses are allowed or disallowed for each BOMwhere-used list.

You can define item status fields as required, optional, or disallowed for a specificapplication area in your company.


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BOM PrerequisitesBefore you create a BOM, you should answer these questions.

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

Bill of Material: Structure

Figure 58: BOM Structure

The large amount of data required in a bill of material is managed in structuredform:

� You enter and maintain data that applies to the entire BOM in the BOMheader.

� You enter and maintain data that applies to an individual component inan item.

� Items can be divided into subitems if partial quantities have differentinstallation points. Subitems have no control functions.


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Figure 59: Subitems

Subitems represent different installation points for partial quantities of an item.For every subitem, you can also maintain a short text next to the subitem quantity.

The sum of the subitem quantities replaces the item quantity.

A subitem has no control functions in the BOM.

This means, for example:

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


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Figure 60: Units of Measure

Hint: The system proposes the base unit of measure from the materialmaster record as a default unit. However, if the alternative unit of measureunit of issue is maintained in the Work Scheduling view, this can be used.

This uses the conversion factor between base unit of measure and unit ofissue, however, which must be entered when you maintain units of issue.

Figure 61: Low-Level Coding


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When you create a BOM, a low-level code is automatically assigned to eachmaterial which is used in MRP and costing.

You can display the administrative data in the material master record.

Low-level codes are used inmaterial requirements planning (MRP) to determinethe sequence in which materials are planned and by product costing to determinehow costs are rolled up. Low-level coding takes account of the fact that a materialmay be used in multiple products and on multiple production levels of one product.

The low-level code is the lowest explosion level on which a material occurs in allproduct structures. Low-level coding collects the total requirements for a materialon the lowest explosion level where it is used.


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Exercise 5: BOM Basics: Display

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

Business ExampleAs a planner, you must be able to display the material BOM. This will provideinsight to the components required in the manufacturing process.

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

1. Go to the bill of material menu.

2. You should see the bill of material categories that the system allows. Whatare they?

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

4. What is the component number of item 0010?

5. What are the component quantity and unit of measure?

6. Is this component a stock item?

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

8. Does a BOM exist for this component?

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

10. What is the valid-to date of this bill of material?

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


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Solution 5: BOM Basics: DisplayTask:Navigate the bill of material for pump T-F1## to become familiar with the SAPECC structure.

1. Go to the bill of material menu.

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

2. You should see the bill of material categories that the system allows. Whatare they?

a) The bill of material categories are:Material BOMDocument BOMEquipment BOMFunctional location BOMOrder BOMWBS BOM

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

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Display.

Field ValueMaterial T-F1##Plant 1000BOM Usage 1

Enter data from the above table and choose

4. What is the component number of item 0010?

a) T-B1##

5. What are the component quantity and unit of measure?

a) 1 PC

6. Is this component a stock item?

a) Yes (item category = L)



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

a) Yes (effective until 31.12.9999)

8. Does a BOM exist for this component?

a) Yes (assembly indicator is set)

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

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

10. What is the valid-to date of this bill of material?

a) Select header then Adm. Data tab.

b) The valid-to date is 31.12.9999.

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

a) Select the Quants/Long txt tab.

b) 1 Pc


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Lesson Summary

You should now be able to:� Describe the organizational layout of the bill of material


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PLM114 Lesson: Managing Bills of Material

Lesson: Managing Bills of Material

Lesson OverviewBills of material must be maintained as accurately as possible. This lessondiscusses the methods for creating and changing BOMs. Other topics includevalidity and engineering change management.


� Demonstrate the validity process and changing an active bill of material� Demonstrate how engineering change management (ECM) affects the

validity of a bill of material� Describe the process of archiving and deleting a bill of material

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

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


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Figure 62: Validity: Area (1)

The area of validity defines which plants can use a bill of material.

You can extend the area of validity by assigning the same bill of material (with thesame internal BOM number) to a material in different plants. If you do this, notethat still only one BOM exists, so any changes you may make will affect all plants.

There must be a plant view for the BOM header and all the item materials ineach plant that the BOM is assigned to.


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Material BOMs can be effective on different organizational levels.

A material BOM can manage data that is directly relevant to production. In thiscase, the area of validity is the plant. The plant is a place of work where all thenecessary work scheduling activities are organized, for example:

� Planning of material requirements� Creation of routings

In this case, you create a plant-specific BOM.

You can also create a group BOM. This is a BOM without reference to any oneplant. This is a good idea, for example, when the engineer/designer is maintaininga BOM in the engineering/design phase. The group BOM can be made effectivefor individual plants using the plant assignment function.


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Plant-specific BOMs are independent of each other and exist separately in thesystem (BOM number). This means that if you make changes to a BOM in plant1000, BOMs in plants 1100, 1500, and 1600 will not be affected.

Figure 65: Validity: Period

The validity period is the time during which the BOM is valid. This period isdefined by the following entries in the BOM header and in the BOM item:

Valid-from dateWhen creating a BOM, this date specifies the point in time from which theBOM header or BOM item is effective.If you create or change a BOM by entering a change number, the systemcopies the valid-from date from the change master record.


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Valid-to dateThis date marks the end of the validity period for the BOM item. The systemcalculates this dynamically.

Hint: The system assigns a default valid-to date of December 31,9999.

If you change a bill of material with a change number that has a valid-fromdate, the validity period of the previous state of the object ends at 0.00 hourson that date.

You can define a valid-from date for an entire BOM and for individual items.

BOM Management - Item DetailsEach BOM item must have anitem category assigned to it. The item categorydefines the features and functions of an item. The item category identifies whetherspecial data must be processed, and controls further system activities.

Figure 66: Item Categories

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

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

detail screens look?


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

Figure 67: Non-Stock Items / Item Category: N

You can create non-stock items both with and without a material master record.If you create a non-stock item without entering a material number, you mustenter a descriptive text and purchasing data.

Using the price data (purchasing data) entered, the system calculates the releasestrategy. The material group is necessary for creating a purchase requisition.

The component is procured directly for the production order. Purchase requisitionsare created automatically.

Figure 68: Variable-Size Item/Item Category R


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

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

Advantages:

� MRP can be executed by exploding the BOM without any additional worksteps.

� You do not have to create a separate material master record for each sizeyou cut.

� All calculations use the variable-size item quantity.

Figure 69: Document Item/Item Category D

If you want to document the product or a component, choose item category D.

Prerequisites for documenting a product or component are as follows:

A document info record must exist for the document, and be maintained indocument management.

The document info record contains basic information for integration into thebusiness process, for example, information about the processing state and thestorage location. Depending on the document type, you can manage various typesof document data (such as technical drawings, photos, or texts). You can use thesedocuments to describe an object comprehensively.

You can display the document on the screen.


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Figure 70: Class Item/Item Category K

A class item has characteristics and is used in a configurable BOM.

You can use classes that have materials or documents classified in them (with classtypes 200, 201, and 300) as class items.

When you configure a BOM, the class node can be replaced by a specific materialor document.

Figure 71: Recursion

A BOM is recursive if the product contains a component that has the same objectnumber as the product. Recursion may be an error, but in some cases it may beintentional.

If the system recognizes the recursion online, you see this message:


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Error: BOM is recursive

In exceptional cases, recursion can be recognized only by the update program. Theperson who creates the recursive BOM receives a message.

If you want to create a recursive BOM, set the Recursiveness allowed indicatorin the BOM item.

Figure 72: Item Control Indicators

The various item categories can be combined with various indicators. Thus specialprocedures can be controlled.

Screens:

B = Basic data

S = Status/lng text

You can set most control indicators in the material master. Most are not copiedto the BOM.

You can make settings for MRP data on the Basic Data screen for the BOM itemthat override the indicators in the material master record.

Do not explode phantom assembly.

Individual requirements indicator

Direct production (special procurement key SOBSL 52)

Long-term planning


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Overview of ECM in Bills of Material

Figure 73: Why Use Engineering Change Management?

Engineering change management is a central logistics function that can be used tochange various master data and document the changes.

By using a valid-from date for the change master record (or for the ECR/ECO),the changes become valid on a predefined date. This aids long-term planning.

You can use engineering change management to store SAP objects (for example,BOMs and routings) more than once. This means that the objects can be storedin all relevant change states.

Changes take effect automatically at the predefined time right across the supplychain, for example, in the sales order, material requirements planning, and shopfloor control.

You can use engineering change management to group together changes todifferent SAP objects that are affected by one change. You can change allobjects at the same time, or you can define different change dates for individualobjects. You can create general documentation for the change and also specialdocumentation for each specific object change.

You can use engineering change management to fulfill your legal obligationsto document changes.


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Figure 74: Engineering Change Management

You can make object changes (for example, BOM changes and routing changes) inthe system either with or without history. Note that change documents are createdby the system, even for changes without history.

Changes without history do not have to be documented because they take placeduring the development stage of the product, for example.

The state of the object before the change is not saved. You can only find outabout the status of the object before the change indirectly, by using the changedocuments.

Changes with history must be documented because they take place duringproduction, for example.

Both the state before the change and the state after the change are saved. Inaddition, the system creates change documents. For some objects, these changedocuments differ from documents created for changes without history.

Engineering change management in the SAP system enables you to documentchanges completely, to cover product liability requirements, for example.


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Figure 75: Structure of Change Master Record

General details about the change are contained in the Change header for thechange number. This includes a brief description of the change, as well as validityor status indicator.

You determine which objects can be changed with the change master record byselecting the object types.

The object management records specify the objects to be changed. Thesecontain exact details such as which BOM is changed in which where-used list.These object management records can either be created by the user or generatedautomatically by the system.

Alternative dates allow you to control the valid-from date for individual objectsmore exactly.


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Figure 76: BOM - Validity Period of Elements

� If you process a BOM with reference to a change number, the systemproduces the valid BOM header and the valid items on the valid-from date.In this example, two valid items (items A and C) exist for the date of changenumber N-2.

� Item B may have been created

� Without engineering change management by a change valid from 1.3.� With a change number such as N4 and a corresponding date� With one of the above change numbers and date element

� Make the settings for processing in engineering change management inCustomizing for the BOM. Basic settings are made in the modificationparameters. These include activating engineering change management forBOM processing, which results in a history requirement for BOMs. You canalso specify whether a change number is assigned when a BOM is created.In the history requirement you can make settings for BOM usage (e.g.production), so that a change number has to be allocated for a certain status,even if it has not previously been processed with a change number.

� In exceptional cases you can allow a BOM change without a changenumber using the authorization object C_STUE_NOH for BOMs withhistory requirements. Remember that, in this case, the changes will notbe documented fully.


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Deleting the Bill of MaterialBills of material can be deleted in several ways.

� You can delete bills of material using:

� The deletion function� Deletion flags

� You can:

� Delete the entire BOM� Delete individual items

� BOMs can be deleted:

� Without history� With history using engineering change management

� Authorization groups control who can delete a bill of material

Using the delete function, the BOM is removed from the system immediately. Ifengineering change management is used, the BOM is deleted on the valid-fromdate of the change master record.

If you set the deletion indicator in the BOM header, the BOM is deleted during thenext reorganization run.

Deletion at header level removes the entire BOM, whereas deletion at item levelremoves only the specified item.

If you delete a BOM without history (without a change master record) the deletionis carried out immediately. Once the deletion has been executed, you can create anew BOM for the same material, plant, and where-used list.

If you delete a BOM with history (and so with a change master record) the systemdeletes the bill of material on the valid-from date of the change master record.

Before deleting a BOM, the system checks for:

� Items with object dependencies to check whether the change master supportsmaintenance of dependencies for configurable BOMs.

� Items with operation assignments. If assignments exist, the system displaysthe relevant message.

See the SAP Library for more information.

You can find out more about SAP document management in the PLM120 course.


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Exercise 6: Changing Bills of Material

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create a group BOM� Assign the BOM to a plant� Change a bill of material

Business ExampleYour company's BOMs are similar across multiple plants. You want to create agroup BOM as a template that can then be copied or assigned to the appropriateplants as necessary.

Task 1:Create a bill of material.

1. Create a group BOM for material T-F## (## = group number).

Note the following when you create a group BOM:

Field User EntryPlant group BOM has no entry for plantUsage 1 (Production)Alternative No entryValid from Today's date

2. Which system message do you get, and why? Ensure no error messagesappear.

3. Enter the following components in the general item overview for BOMT-F##:

Item no. Item cat. Component Quantity Sort string10 L 100-100 1 A520 L 100-200 2 A130 L 100-300 1 A3

Save the BOM and display the header using the transaction Changematerial BOM.



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

4. You are not sure if the fly wheel component of your pump is the rightmaterial. Branch off to the material master record to check the materialgroup. Do not exit the current transaction and do not create another session.

What is the name of the material group? _________

5. Return to the BOM and save your work.

Task 2:Create and change plant validity.

1. Assign the group BOM to plants 1000 and 1100.

2. Why can you not assign it to plant 1100?

3. Go to the BOM header for plant 1000.

What is the internal BOM number? _______________

Why? _______________

4. Delete the plant assignment (plant 1000).

5. Create a plant -specific BOM for T-F## in plant 1000. Use the group BOMas a template. Make the following plant-specific changes:

Change the quantity of item 20 from 2 to 1.

Maintain item 20 with spare part indicator �A�

Sort the BOM according to the sort string.

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

1. Change BOM T-F## in plant 1000.

2. Add component 100-600.



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Item no. Item cat. Component Quantity40 L 100-600 2

The two support bases are mounted on the pump.

The two support bases should be assembled at the front and the back ofthe pump.

Create subitems for this.

3. Add a non-stock item by entering the data below.

Item no. Item cat. Component Quantity50 N 1

Item text One non-stock itemPurchasing org. 1000

Price 10 EUR

Purchasing group 000

Cost element 415000

Material group Metal processing

4. Add a variable sized item, 100-700, with the dimensions below.

Item no. Item cat. Component Quantity60 R 100-700 1 piece

Size 1 200 mmSize 2 300 mm

Note the calculated variable-size item quantity.

Change variable size from 300 to 400mm.

Get the system to recalculate the variable-size item quantity.

5. Add bulk material component 100-130.




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6. Add drawing document T-F1## to the BOM and save.

Item no. Itemcat.

Document Typ DPt Vs Quan-tity

80 D T-F1## DRW 000 00 1

7. Display your BOM, T-F##, with 15 as the required quantity.

Who created the BOM? _________________

On what date? ________________

Task 4:In two months, component 100-100 will be replaced by T-B##. Change the BOMwith history to take place at the appropriate time.

1. First, create an Engineering Change Number ECN## that is valid forchanging material masters, BOM's, and routings, and has a validity date 2months from today.

2. Use your Engineering Change Number, ECN## to change the BOM forT-F## by replacing 100-100 with T-B##.

3. Check your BOM for T-F## to view the results.


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Solution 6: Changing Bills of MaterialTask 1:Create a bill of material.

1. Create a group BOM for material T-F## (## = group number).

Note the following when you create a group BOM:

Field User EntryPlant group BOM has no entry for plantUsage 1 (Production)Alternative No entryValid from Today's date

a) Choose Logistics→ Production→ Master data→ Bills of material→Bill of material→ Material BOM→ Create .

b) Enter the data from the table below.

Field User EntryMaterial T-F##

Plant <blank>Usage 1

Valid from Today's date

c) Choose Enter .

2. Which system message do you get, and why? Ensure no error messagesappear.

a) W: Group BOM

The warning message regarding group BOMs can be deactivated fromSAP R/3 4.7 onwards.

Choose Enter to continue.

3. Enter the following components in the general item overview for BOMT-F##:



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Item no. Item cat. Component Quantity Sort string10 L 100-100 1 A520 L 100-200 2 A130 L 100-300 1 A3

Save the BOM and display the header using the transaction Changematerial BOM.

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

a) In the general item overview, enter the data from the table above.

b) Save your BOM by choosing .

c) From the Create material BOM: Initial screen, choose Material BOM→ Change.

Select Enter twice to access your BOM in change mode.

d) Select the Header icon . The BOM number is displayed in theBOM field under the material number.

BOM Number: ___________________

4. You are not sure if the fly wheel component of your pump is the rightmaterial. Branch off to the material master record to check the materialgroup. Do not exit the current transaction and do not create another session.

What is the name of the material group? _________

a) Choose the button.

Select component 100-100 and choose Environment→ DisplayMaterial→ Basic data or double-click on the material number.

b) In the material master Basic Data 1 view, you can see that the materialgroup is 001 (Metal processing).

5. Return to the BOM and save your work.

a) Green arrow back to return to the BOM.

b) Choose Save .



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Task 2:Create and change plant validity.

1. Assign the group BOM to plants 1000 and 1100.

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Plant assignment→ Create.

b) Enter the material number and BOM usage = 1. Do not enter the plantin the top portion of the screen.

Enter the plant in the Assign to to section and press Enter .

c) Select the checkbox next to the plant and choose Save.

2. Why can you not assign it to plant 1100?

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

3. Go to the BOM header for plant 1000.

What is the internal BOM number? _______________

Why? _______________

a) Choose Logistics→ Production→ Master data→ Bills of material→Bill of material→ Material BOM→ Display.

Choose Header .

b) The internal BOM number in plant 1000 is the same as the numberfrom exercise step 1-2. A reference has been created. The BOMstructure is saved under one number in the system.



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4. Delete the plant assignment (plant 1000).

a) Change the plant assignment: Logistics→ Production→ Master data→ Bills of material→ Bill of material→ Material BOM→ Plantassignment→ Change.


Field ValueMaterial T-F##

Plant <leave blank>Usage 1

Choose Enter.

c) Display all assignments by choosing the All Allocs to BOM button.

Select and delete the assignment to plant 1000 by choosing the Deleteallocation button.

d) Go back to the Current allocations and choose Save .

5. Create a plant -specific BOM for T-F## in plant 1000. Use the group BOMas a template. Make the following plant-specific changes:


Maintain item 20 with spare part indicator �A�



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Sort the BOM according to the sort string.

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Create.

Enter the data from the table below.


Plant 1000

Usage 1


Select the copy from icon or press F7.

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

Usage 1 and choose Enter .

Hint: Do not enter the plant in the copy from box.

Select all of the components to copy and press the Copy icon again.

b) Make the following changes:


Maintain item 20 with spare part indicator �A�. Double-click in theitem number to access the item details. Select the Status/Lng Text tab.Enter A in the spare part indicator field.

c) Sort the BOM according to the sort string. Choose Back toreturn the General item Overview screen. Choose Edit→ Sort→ Sortby Sort string.

d) Save the BOM by choosing Save .



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

1. Change BOM T-F## in plant 1000.

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Change.



Plant 1000

BOM Usage 1

c) Choose Enter .

2. Add component 100-600.


The two support bases are mounted on the pump.

The two support bases should be assembled at the front and the back ofthe pump.



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Create subitems for this.

a)


Select item 40 and choose the Sub-items button.

SubI Installation point Sub-item qty Sub-item text0001 Front of pump 20002 Back of pump 1

Note: The item quantity is changed from 2 PCS to 3 PCSand a message is displayed.

Green arrow back or press F3.

Note: Quantity is 3 and grayed out.

3. Add a non-stock item by entering the data below.


Item text One non-stock itemPurchasing org. 1000

Price 10 EUR



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Item text One non-stock itemPurchasing group 000

Cost element 415000

Material group Metal processing

a) Enter data from the table below.


Choose Enter .

b) A detailed screen will appear. Enter Copper Plated Pressure

Plate in the Item text: Line 1 field. Choose Enter .

c) A detailed purchasing screen in now displayed. Enter data as specifiedin the table below.

Field ValuePurchasing organization 1000

Price 10 EUR

Purchasing group 000 Chef, H.Cost element 415000

Material group 001 (Metal processing)

Press Enter .

4. Add a variable sized item, 100-700, with the dimensions below.


Size 1 200 mmSize 2 300 mm

Note the calculated variable-size item quantity.

Change variable size from 300 to 400mm.



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Get the system to recalculate the variable-size item quantity.

a) Enter the following in the General Item Overview.


The screen variable-size item data is displayed. Enter the sizes below:

Size 1: 200 mmSize 2: 300 mm

Choose Enter. The Qty Var-sz Item is calculated to 0.06 M2.

Warning message:Deletevariable size itemquantity!

Variable size item quantity: 0.080 m2

b) Change size from 2 to 400mm and press ENTER.

Note the message and that the variable quantity has not beenrecalculated. To recalculate the variable quantity, delete the existingvalue (0.06) and press ENTER. The variable quantity is recalculated to0.08 M2.

5. Add bulk material component 100-130.



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a) Enter the data below:


b) Select item and choose Item or double-click on Item. 70.

c) Select the Status/lng text tab page.

d) Select the Bulk material indicator (bottom right).

e) Remove the CostingRelevancy indicator.

f) Arrow back or press F3.

6. Add drawing document T-F1## to the BOM and save.

Item no. Itemcat.

Document Typ DPt Vs Quan-tity

80 D T-F1## DRW 000 00 1

a) Select the Document tab page.

Enter data below:

Itemno.

Itemcat.

Docu-ment

Typ DPt Vs Quan-tity

80 D T-F1## DRW 000 00 1

b) Choose Save .

7. Display your BOM, T-F##, with 15 as the required quantity.

Who created the BOM? _________________



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On what date? ________________

a) Display material BOM by choosing Logistics→ Production→ MasterData→ Bills of Material→ Bill of material→ Material BOM→Display .


Required quantity 15 (bottom line)

From the Header, choose the Administrative data tab page.

Task 4:In two months, component 100-100 will be replaced by T-B##. Change the BOMwith history to take place at the appropriate time.

1. First, create an Engineering Change Number ECN## that is valid forchanging material masters, BOM's, and routings, and has a validity date 2months from today.

a) Use the menu path Cross-Application Components→ EngineeringChange Management→ Change Number→ Create or transactioncode CC01.

b) Enter ECN## as the Change Number. Be sure the Change Master andWithout Release Key indicators both default and click Enter .

c) Enter the description GR## ECN, a valid from date two months fromtoday, and Change no. status 01 and click Enter .

d) Select Object types and set the Actv. indicator for Bill of Material,Task List, and Material. Click Save

.

2. Use your Engineering Change Number, ECN## to change the BOM forT-F## by replacing 100-100 with T-B##.

a) Choose Logistics→ Production→ Master Data→ Bills of Material→ Bill of Material→ Material BOM→ Change or use transactioncode CS02.

b) Enter the material T-B##, plant 1000, usage 1, change numberECN##, and choose Enter .

c) Hit enter to work through the warning.

d) Replace component 100-100 with T-B## and Save.



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3. Check your BOM for T-F## to view the results.

a) Choose Logistics→ Production→ Master Data→ Bills of Material→ Bill of Material→ Material BOM→ Display or use transactioncode CS03.

b) Enter the material T-B##, plant 1000, usage 1, valid from datetoday valid to date 2 months from today, and choose Enter .

c) Check the validity dates of the components.


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Lesson Summary

You should now be able to:� Demonstrate the validity process and changing an active bill of material� Demonstrate how engineering change management (ECM) affects the

validity of a bill of material� Describe the process of archiving and deleting a bill of material


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Lesson: BOM Reporting

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


� Demonstrate the various bill of material reports that are available toindividuals

� Demonstrate the comparative reporting tools for bills of material

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

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

Figure 77: BOM Explosion


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PLM114 Lesson: BOM Reporting

This question arises in various situations, such as when:

� You need to determine the requirements for a product.� The engineering design department needs to look at the overall structure

of a product.� You need an overview of all the necessary parts and materials.� You need to calculate costs or effects of cost changes.

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

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

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

Figure 78: Where-Used Lists

You can create where-used lists for:

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


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

Figure 79: Single-Level and Multilevel Material Where-Used Lists

The where-used list provides an answer to this question: Where is a material usedand in what quantity? This question arises especially where there are a lot ofmultiple-use parts and materials.

Examples of situations where this information is required:

� To calculate the requirements for a particular material� To find the products that are affected by a change to an individual part� To find the assemblies that will be produced late because, for example,

delivery of a raw material is delayed� To calculate the cost effects on a product if raw materials costs change

Comparing Bills of MaterialThe BOM comparison is useful if:

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


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Figure 80: BOM Comparison

The comparison can be single-level or multilevel.

You can select which fields you want to compare.


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Exercise 7: Multilevel BOM Reporting

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

Business ExampleYou are responsible for managing BOMs. As part of the process, evaluations arerequired to understand where components are used and compare bills of materialfor similar products.

Task 1:Execute and navigate various BOM reports.

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

2. Which items in multilevel BOM T-F## (plant 1000) have spare partindicator A?

3. Which items are non-stock items?

4. Which item is handled as bulk material?



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

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

Task 2:BOM Comparison.

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


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Solution 7: Multilevel BOM ReportingTask 1:Execute and navigate various BOM reports.

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

a) Choose Logistics→ Production→ Master Data→ Bills of Material→ Reporting→ BOM Explosion→ Material BOM→ BOM Level byLevel.

b) Enter the Material: T-F##(Default)

Plant: 1000 (Default)

Application: PP01 (Production � general)

c) Access the report via Execute or press F8.

2. Which items in multilevel BOM T-F## (plant 1000) have spare partindicator A?

Answer: Green arrow back (or press F3) to the Explode BOM: Levelby Level: Initial screen.

Select View .Enter A (Spare part customer A) in the Spare Part ID. field.(To see ALL spare parts, enter X in the Spare part sel. field.)

Choose Execute .Fly wheel: 100-200

3. Which items are non-stock items?

Answer: Green arrow back (or press F3) to the Explode BOM: Levelby Level: View screen.Delete the spare part entry.Enter Item category N (non-stock item).

Choose Execute .



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4. Which item is handled as bulk material?

Answer: Green arrow back (or press F3) to the Explode BOM: Level byLevel: View screen.Delete the non-stock entry.Select the box next to Bulk Material.

Choose Execute .Hexagon head screw M10: 100-130.

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

Answer: Choose Logistics→ Production→ Master Data→ Bills ofMaterial→ Reporting→ BOM Explosion→ Material BOM→ SummarizedBOM.Enter the following:Material: T-F##Plant: 1000Application: PP01Required quantity: 10

Choose Execute .The answer may vary: approximately 110, including totals indicator.

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

Answer: Choose Logistics→ Production→ Master Data→ Bills ofMaterial→ Reporting→ Where-Used List→ Material.Enter the following:Material: 100-130Type of where-used list: Direct

Select next screen .Enter Required qty: 1 and Plant: 1000.Choose Execute.



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Task 2:BOM Comparison.

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

a) ChooseLogistics→ Production→ Master Data→ Bills of Material→Reporting→ BOM Comparison.

b) Enter the following in the Primary BOM area:

Material: T-F##

Plant: <Blank>

Usage: 1

Change Number: <Blank>

c) Enter the following in the Secondary BOM area:

Material: T-F##

Plant: 1000

Usage: 1

Change Number: <Blank>

d) Choose Summarized Comparison .

e)

1. Components with equal quantities are represented by the icon.2. Same component but with different quantities are represented

by the icon.3. Components that are required on one BOM but not the other

display the icon.


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Lesson Summary

You should now be able to:� Demonstrate the various bill of material reports that are available to

individuals� Demonstrate the comparative reporting tools for bills of material


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PLM114 Lesson: Configuration of the Bill of Material

Lesson: Configuration of the Bill of Material

Lesson OverviewThis lesson discusses the detailed configuration of the bill of material.


� Describe the configuration activities surrounding the BOM header� Describe the configuration activities surrounding the BOM items

Business ExampleAs the project lead for implementing bills of material, you must be aware of thestructural design of the object in SAP ECC. In doing so, you will learn how the billof material is structured to integrate with several business areas in your company.Your company has requirements to use bills of material for costing, engineeringand production. To support these integrated functions, you must be aware of whatconfiguration options are available to your company.

The BOM Header: Defining Modification ParametersYou can do the following by making the corresponding settings in the modificationparameters:

� Control the validity of a bill of material� Allow or disallow technical types for bills of material� Maintain the settings for items� Make general BOM settings

In the group box for validity, engineering change management (historyrequirement) for bills of material is defined. The low date setting means that theBOM validity is set to the earliest processing date when it is created by thesystem, that is, 01.01.1900. The low date cannot be changed. The valid-from dateis a default value and can be changed by the user. If the low date is not activated(checkbox blank), the system proposes today's date as the valid-from date.

The technical types multiple BOM and variant BOM can be deactivated. In otherwords, no maintenance of bills of technical BOM typesM and V is possible.

In BOM items, you can use the explosion type of a BOM item to display byvalidity and define which text is displayed for a variable-size item.


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In the general settings, the base unit of measure is defined for BOM headers ofspecial BOM categories, such as equipment BOM and document structure, andfor special item categories. In addition, you can activate the CAD interface forbills of material (material BOMs only).

BOM Default SettingsDefault values for the BOM header and settings for variable-size items are definedin Customizing:

� Base quantity for bill of material� BOM status� Unit of measure for size and number of variable-size items

The following default values can be defined by the user or preset in Customizing:

� Item increment� Item category� Material provision indicator� Various BOM reporting options

You can use default values to organize data entry effectively.

Each user can also define their own default values to optimize or simplify dataentry. However, this requires specific authorization. Alternatively, these settingscan be defined for a user in Customizing.

Configuration Sequence BOMs, BOM Status, BOMItem StatusThe abbreviations in the graphic have the following meanings:

M = Mandatory activity (must)O = Optional activity (optional)D = Default available for activity (default)


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Figure 81: Sequence for Customizing Bills of Material

Hint: When defining the BOM usage, the next stepmust be checking andmaintaining the settings for default values for item status.

At BOM header level, the department or person responsible and the historyrequirement for bills of material can be defined. When you process a bill ofmaterial with history requirement activated an additional authorization objectis checked (C_STUE_NOH). If this authorization is assigned to a user, the usercan change bills of material that have a history requirement without a changemaster record.

The object types for BOM items may not be changed.

The user-specific settings can be defined in Customizing for each user � with ahigh administrative overhead � or each user maintains their own user-specificsettings in the master data functions for bills of material.


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Figure 82: BOM Status and BOM Item Status

The BOM status controls BOM processing in different application areas. Whenyou configure your system in Customizing under Bill of Material→ Define BOMStatus, you define the statuses for different indicators that allow or disallowBOM processing. Examples: BOM A: A BOM with status 1 can be exploded inMRP and released for a planned order. BOM B: A BOM with status 2 cannot beexploded in MRP or released for a planned order.

When you configure your system in Customizing (Bill of Material→ BOM usage→ Define BOM usages), you define which item statuses are allowed or disallowedfor each BOM usage (general setting is valid for all items). Fine-tuned control isdefined for each individual item. You can define item status fields as required,optional, or disallowed for a specific application area in your company.

Hint: When defining the BOM usage, the next stepmust be checking andmaintaining the settings for default values for item status.


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Alternative Determination

Figure 83: Alternative Determination

Alternative selection for cases where several alternative BOMs exist can becontrolled dependent on material/plant/usage and an alternative with validity date.It can also be controlled by other applications, such as the following:

� BOM explosion in general� Inventory management� Engineering� Production� Costing� Maintenance and so on.

In addition, you can specify a selection ID that decides the sequence in which thesystem searches for bills of material if several bills of material have been createdfor one material with different usages. For this purpose, a selection ID with aselection priority is maintained for each BOM usage. The selection priority isentered as a number, whereby the lowest number has the highest priority.

Variable-Size Item/ Item Category �R� Variable-SizeItem with Formula for a CylinderEnter this item category to represent parts of a material of different sizes underone material number.

On the detail screen: After entry, the system calculates variable-size quantity ofthe material consumed by the component usage.


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Figure 84: Variable-Size Item with Formula for a Cylinder

Advantages:

� MRP can be executed by exploding the BOM without any additional worksteps.

� You do not have to create a separate material master for each size.

Entering a formula for variable-size item calculation also enables complexcalculations.

In Customizing for item data, you can define your own formulas and assign themwhen creating new variable-size items.

Caution: You can only use the variables ROMS1 � ROMS3, the constantpi, and the operators +, -, *, and /.

If no formula key is entered, the following formula is used:

� Size 1 for lengths� Size 1 * Size 2 for areas� Size 1 * Size 2 * Size 3 for volumes


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Item CategoriesThe following item categories are defined in the standard system:

� Stock item� Non-stock item� Variable-size item� Text item� Document item� PM structure element� Class item� Intramaterial (PP-PI)

Figure 85: Item Categories

The item category controls:

� Whether a material must, can, or cannot be entered� Whether quantities can be negative or positive or both� Whether quantities can be negative or positive or both� Whether subitems are allowed� Which item detail screens (ItmCtrl) are required for specific item categories.

Example: A variable-size item requires variable-size item data.


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Exercise 8: Bill of Material Configuration

Exercise ObjectivesAfter completing this exercise, you will be able to:� Set the status, application and use of a BOM� Set up default values for a user

Business ExampleYou must adapt the BOM management of your SAP ECC to suit the requirementsof your company and users.

Task 1:When configuring bills of material by defining modification parameters, what isthe effect if you change the modification parameters for BOMs by selecting thefollowing checkboxes?

1. Effectivity (validity): Low date

2. Technical type: Mult. BOM inactive

Task 2:You need to maintain user-specific default values for your user.

1. Set the default settings for your user so that the item increment is 8. Itemcategory L is the default setting when you create a material item andcategory D when you create a document item.

2. Test the user-specific settings by changing your material BOM T-F## inplant 1000 with usage 1.

Task 3:Define BOM usage.

1. With usage Universal, which fields are required fields?

Task 4:In which order of priority are bills of material (BOM usages) selected according tothe selection ID stored for BOM application PP01 (production general)?

1. Which selection ID does the BOM application PP01 use?

2. What is the order of priority of BOM usages?


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Solution 8: Bill of Material ConfigurationTask 1:When configuring bills of material by defining modification parameters, what isthe effect if you change the modification parameters for BOMs by selecting thefollowing checkboxes?

1. Effectivity (validity): Low date

a) In Customizing choose Production→ Basic data→ Bill of material→Control data for bills of material→ Define modification parameters.

Select validity. low date checkbox and press F1 (help).

When BOMs are created or edited, the default date is the earliestprocessing date defined in the system: 01.01.1900.

2. Technical type: Mult. BOM inactive

a) In Customizing choose Production→ Basic data→ Bill of material→Control data for bills of material→ Define modification parameters.

Select technical type: multiple BOM inactive checkbox and press F1(help).

No multiple BOMs can be maintained in ECC; in other words, youcannot maintain alternatives for an existing bill of material.



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Task 2:You need to maintain user-specific default values for your user.

1. Set the default settings for your user so that the item increment is 8. Itemcategory L is the default setting when you create a material item andcategory D when you create a document item.

a) Set up the default values for a user in Customizing: choose Production→ Basic data→ Bill of material→ Define user-specific settings.

Caution: The same settings can be maintained by the user inthe application for creating or changing a bill of material,provided that the user has the authorization for this. On theChange/Display Material BOM initial screen, choose Settings→ Current settings. You can also get to the default values fromthe SAP Easy Access screen: choose Production→ Masterdata→ Bills of material→ Environment→ Current settings→ User-specific settings (transaction OS29).

Highlight the settings for an existing user.

Click Copy As

Replace existing user with your user ID.

Choose Enter . Make the appropriate changes and choose Save.

2. Test the user-specific settings by changing your material BOM T-F## inplant 1000 with usage 1.

a) Change the BOM T-F2##.

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

Results: Item increments for all subsequent new items are set atintervals of 8. For material items, item category L is proposed; fordocument items, item category D is proposed.

Task 3:Define BOM usage.

1. With usage Universal, which fields are required fields?

a) In Customizing, choose Production→ Basic data→ Bill of material→ General data→ BOM usage→ Define BOM usage.

When universal is used, no field is set as mandatory because all fieldswith � , � are optional entries, except PM relevancy, which cannotbe entered.



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Task 4:In which order of priority are bills of material (BOM usages) selected according tothe selection ID stored for BOM application PP01 (production general)?

1. Which selection ID does the BOM application PP01 use?

a) In Customizing, choose Production→ Basic data→ Bill of material→ Alternative determination→ Define applications.

Results: PP01 uses selection ID 01.

2. What is the order of priority of BOM usages?

a) In Customizing, choose Production→ Basic data→ Bill of material→Alternative determination→ Define order of priority for BOM usages.

The order of priority of the SelID (selection ID) is:

1 (Production)3 (Universal)2 (Engineering/design)

Example: If a material has several bills of material with differentusages (one internal BOM number for each usage), the system searchesfor a production BOM first, then for a universal BOM, and then for anengineering/design BOM.


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Lesson Summary

You should now be able to:� Describe the configuration activities surrounding the BOM header� Describe the configuration activities surrounding the BOM items


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Unit Summary PLM114

Unit SummaryYou should now be able to:� Describe the organizational layout of the bill of material� Demonstrate the validity process and changing an active bill of material� Demonstrate how engineering change management (ECM) affects the

validity of a bill of material� Describe the process of archiving and deleting a bill of material� Demonstrate the various bill of material reports that are available to

individuals� Demonstrate the comparative reporting tools for bills of material� Describe the configuration activities surrounding the BOM header� Describe the configuration activities surrounding the BOM items


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Test Your Knowledge

1. A bill of material is a complete, formally structured list of components thatmake up a product or assembly.Determine whether this statement is true or false.□ True□ False

2. All of the components are stored in a multilevel bill of material for thefinished goods.Determine whether this statement is true or false.□ True□ False

3. A material BOM is the only BOM category that can be created in the SAPECC system.Determine whether this statement is true or false.□ True□ False

4. A material BOM can have many different usages for specific departmentswithin a company.Determine whether this statement is true or false.□ True□ False

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

6. At minimum a basic data view of a material master record must exist beforeyou can create a BOM for that material.Determine whether this statement is true or false.□ True□ False


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7. The base unit of measure defaults into the BOM item but can be overriddenwith the issue unit of measure from the work scheduling view if it ispopulated.Determine whether this statement is true or false.□ True□ False

8. Each time a BOM is saved the system calculates the low level code whichis used for planning.Determine whether this statement is true or false.□ True□ False

9. The area of validity is:Choose the correct answer(s).□ A The materials that can use a BOM□ B The plants that can use a BOM□ C The materials that are used by a BOM as components□ D The industry that can use a BOM

10. The validity period is:Choose the correct answer(s).□ A The materials that can use a BOM□ B The plants that can use a BOM□ C The time during which a BOM can be used to create an order□ D The time during which a BOM is created

11. Select each of the following that is not an item category.Choose the correct answer(s).□ A Stock item□ B Non-stock item□ C Class item□ D Non-class item□ E Text item

12. Once an item category is assigned to a BOM item it cannot be changed.Determine whether this statement is true or false.□ True□ False


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13. A variable sized item category requires you to enter the dimensions of theitem.Determine whether this statement is true or false.□ True□ False

14. A non-stock item category does not require a material number.Determine whether this statement is true or false.□ True□ False

15. A recursive component on a BOM appears twice as a component with twodifferent item numbers.Determine whether this statement is true or false.□ True□ False

16. Select each of the following that is a reason to use engineering changemanagement.Choose the correct answer(s).□ A Monitoring and documentation of changes□ B Planning and execution at a specific point in time□ C You can save several change statuses for the same object.□ D Integration in the logical process chain□ E All of the above□ F None of the above

17. When making a change to a BOM using a change number the validity dateson the BOM are changed to match the key date in the change number.Determine whether this statement is true or false.□ True□ False


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18. Select each of the following that are ways to delete a BOM.Choose the correct answer(s).□ A Delete the entire BOM□ B Delete a BOM item□ C Set the deletion indicator□ D Delete with a change number□ E Archive the BOM

19. Which report would you use to determine which BOMs will be affected by acomponent change?Choose the correct answer(s).□ A BOM comparison□ B Level by level BOM explosion□ C Multilevel BOM explosion□ D Material where-used list

20. Which report would you use to see an overview of all the necessary partsand materials?Choose the correct answer(s).□ A BOM comparison□ B Level by level BOM explosion□ C Multilevel BOM explosion□ D Material where-used list

21. Which report would you use to see the differences between two BOMs withdifferent change statuses?Choose the correct answer(s).□ A BOM comparison□ B Level by level BOM explosion□ C Multilevel BOM explosion□ D Material where-used list

22. Which of the following are required to be configured before you can create aBOM?Choose the correct answer(s).□ A BOM usage□ B BOM status□ C Item Categories□ D User-specific settings□ E None of the above


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23. You can control which material types can be used as the header materialwhen creating a BOM.Determine whether this statement is true or false.□ True□ False

24. A material with any material type can be used as a BOM component andthis cannot be changed in the system.Determine whether this statement is true or false.□ True□ False

25. Which of the following can be set in the user-specific settings?Choose the correct answer(s).□ A Item increment□ B Default item category for materials□ C Default BOM usage□ D Default BOM category


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Answers

1. A bill of material is a complete, formally structured list of components thatmake up a product or assembly.

Answer: True

A bill of material is a complete, formally structured list of components thatmake up a product or assembly.

2. All of the components are stored in a multilevel bill of material for thefinished goods.

Answer: False

All bills of material are stored as single-level BOMs in the system. So theBOM for the finished goods consists of its direct components, each of whichmay have its own single-level BOM in the system. This linkage creates amultilevel BOM and can be viewed by using BOM reporting.

3. A material BOM is the only BOM category that can be created in the SAPECC system.

Answer: False

The BOM categories that can be created in the SAP ECC system are material,order, document, equipment, and functional location BOMs.

4. A material BOM can have many different usages for specific departmentswithin a company.

Answer: True

A material BOM can have production, engineering, costing, sales, plantmaintenance usages

5. Each material BOM is material and plant unique and each material plantcombination BOM has a separate internal number assigned to it.

Answer: False

Each material BOM is unique for the material, plant, usage combination andeach of those combinations had a unique internal group number.


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6. At minimum a basic data view of a material master record must exist beforeyou can create a BOM for that material.

Answer: True

At minimum a basic data view of the material master must exist beforeyou can create a BOM for that material. If only the basic data view exists,only a group BOM can be created and cannot be allocated to a plant until aplant specific view exists.

7. The base unit of measure defaults into the BOM item but can be overriddenwith the issue unit of measure from the work scheduling view if it ispopulated.

Answer: True

The system proposes the base unit of measure from the material masterrecord as the default unit. However, if the alternative unit of measure unit ofissue is maintained in the Work Scheduling view, this can be used.

8. Each time a BOM is saved the system calculates the low level code whichis used for planning.

Answer: True

When you create a BOM a low level code is automatically assigned to eachmaterial used in MRP and costing.

9. The area of validity is:

Answer: B

The area of validity defines which plants can use a bill of material.

10. The validity period is:

Answer: C

The validity period is the time during which the BOM is valid to create anorder and is defined in the BOM header.


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11. Select each of the following that is not an item category.

Answer: D

The BOM item categories are L stock item, N non-stock item, R variablesized item, T text item, D document item, K class item, I a PM structureelement, and M phantom or intra-material. Non-class item is not an itemcategory in the SAP ECC system.

12. Once an item category is assigned to a BOM item it cannot be changed.

Answer: True

You cannot change the item category after you have entered the item. Youcan only correct an entry for the item category by deleting the item and thencreating a new one.

13. A variable sized item category requires you to enter the dimensions of theitem.

Answer: True

When you enter an item with variable sized item category the systemgives you a chance to enter 3 dimensions for the product and a formulafor calculation.

14. A non-stock item category does not require a material number.

Answer: True

You can create non-stock items both with or without a materials masterrecord. If you create a non-stock item without entering a material number,you must enter a descriptive text and purchasing data.

15. A recursive component on a BOM appears twice as a component with twodifferent item numbers.

Answer: False

A BOM is recursive if the product contains a component that has the sameobject number as the product, i.e., when a component and the headermaterials have the same material number.


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16. Select each of the following that is a reason to use engineering changemanagement.

Answer: E

All of the above are reasons to use engineering change management.

17. When making a change to a BOM using a change number the validity dateson the BOM are changed to match the key date in the change number.

Answer: True

The date in the change number becomes the validity date for the BOM itemand header.

18. Select each of the following that are ways to delete a BOM.

Answer: A, B, C, D

You can delete a BOM using the deletion function or the deletion indicator.You can delete the entire BOM or delete individual items. BOMs canbe deleted without history or with history using engineering changemanagement. Archiving a BOM is saving a copy of it when you removeit from the database.

19. Which report would you use to determine which BOMs will be affected by acomponent change?

Answer: D

The where-used list provides an answer to the questions, where a material isused and in what quantity. It can be used to find the products that are affectedby a change to an individual part.

20. Which report would you use to see an overview of all the necessary partsand materials?

Answer: C

The BOM explosion answers the questions, what a product consists of. Toget an overview of the entire structure of all necessary parts and materialsa multilevel BOM explosion report is available.


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21. Which report would you use to see the differences between two BOMs withdifferent change statuses?

Answer: A

The BOM comparison is useful if two BOMs have different change statuses.The comparison can be either single-level or multilevel.

22. Which of the following are required to be configured before you can create aBOM?

Answer: E

Since all of the above can use the default settings delivered with your SAPECC system or are optional configuration activities, none of them is required.

23. You can control which material types can be used as the header materialwhen creating a BOM.

Answer: True

In Materials types for use in BOMs, you can indicate which material typescan be used as the header material in a BOM.

24. A material with any material type can be used as a BOM component andthis cannot be changed in the system.

Answer: False

In material types for BOM items, you can control which material types canbe entered as components on the BOM.

25. Which of the following can be set in the user-specific settings?

Answer: A, B

The item increment and the default item category for materials as well asseveral other settings can be set in the user-specific settings. It is not possibleto default the BOM usage and BOM category in the user-specific settingssince these are picked by the transaction or the entry screen prior to BOMmaintenance.


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Unit 5Modeling the Manufacturing Process

Unit OverviewThis unit introduces the concept of the SAP ERP work center and how it isused in the task list. You will be instructed on the creation, maintenance, andconfiguration of the work center. You will also execute various transactions tomanage the process surrounding its life cycle.


� Describe the purpose and integration points of the task list (routing)� Describe the structure and purpose of the work center� Describe the purpose of the standard value key and standard values� Describe the purpose of defaults in the work center� Create standard texts to describe a process step� Describe capacities and demonstrate their maintenance� Describe the function of a pooled work center� Describe a reference work center� Use reference and pooled capacities� Describe the how the work center integrates with costing� Demonstrate how the work center and the task list interact with the cost center� Define default values for work centers� Explain the configuration settings regarding work centers� Create and test work center formulas

Unit ContentsLesson: Modeling Manufacturing ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215Lesson: Basic Work Center Data and Defaults . .. . . . . . . . . . . . . . . . . . . . . . . . . . .221

Exercise 9: Create a Work Center .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229Lesson: Capacities in the Work Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238

Exercise 10: Capacities in the Work Center .. . . . . . . . . . . . . . . . . . . . . . . . . . .241Lesson: Integrating Costing with the Work Center .. . . . . . . . . . . . . . . . . . . . . . . .250


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Unit 5: Modeling the Manufacturing Process PLM114

Lesson: Configuring the Work Center .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253Exercise 11: Optional: Work Center Formulas .. . . . . . . . . . . . . . . . . . . . . . . .265Exercise 12: Work Center Category and Field Selection Control,Default Work Center (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271


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PLM114 Lesson: Modeling Manufacturing

Lesson: Modeling Manufacturing

Lesson OverviewThis lesson provides a basic definition and introduction to SAP ERP work centersand task lists (routings).


� Describe the purpose and integration points of the task list (routing)� Describe the structure and purpose of the work center

Business ExampleAs the project lead for implementing manufacturing resources, you must be awareof the structural design of the work center object in SAP ERP. You need to learnhow the task list and work center are structured to integrate with several businessareas in your company. Your company has requirements to use task list and workcenters for costing, engineering, and production.

Introduction to Modeling ManufacturingIn manufacturing, everything revolves around master data, which determines therelationships between the materials used in production and the production process.Material masters must exist before a bill of material and its components can becreated.


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Figure 86: Data: Modeling Manufacturing

Bills of materials indicate what materials are used to produce a product. Thecomponents in a BOM can be assigned to specific operations where they arerequired.

Work centers must be defined before they can be used in an operation.

Routings are more complex and pull the other pieces of master data together.Routings define the operational steps required to produce the item, along withthe time required, work center where the work is done, and other manufacturingcontrol data.

Production resources and tools identify the tools needed to do the work. Theycan be assigned to operations.

Documents created in document management can be assigned as components inBOMs, or as a production resource tool (PRT) to routing operations.

Standard SAP R/3 texts can be created and assigned to PP basic data objects. TheSAP R/3 classification system can be used to group PP basic data according touser-defined attributes.

For the material you want to produce, you must set the procurement type toin-house production (X,E). You must maintain at least one plant-specific view(MRP and/or work scheduling) in the accounting and costing views for thematerial.


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Figure 87: Work Center

A work center is a location that defines where production activities take placeaccording to order requirements. In different companies, work centers are alsocalled machine centers or capacity centers.

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

Figure 88: Work Center Integration


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Work centers are integrated with and support a number of areas, most commonlyscheduling, capacity planning, and costing.

Figure 89: Routing

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

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


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Figure 90: Routing Usage

Routings are critical to a number of functional activities within SAP ERP. Theseform the basis for:

� Lead time scheduling� Product costing� Capacity planning


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Lesson Summary

You should now be able to:� Describe the purpose and integration points of the task list (routing)� Describe the structure and purpose of the work center


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PLM114 Lesson: Basic Work Center Data and Defaults

Lesson: Basic Work Center Data and Defaults

Lesson OverviewIn this lesson you will learn what data is contained in a work center, what isrequired, and how the data is used. You will also learn how to create a newwork center.


� Describe the purpose of the standard value key and standard values� Describe the purpose of defaults in the work center� Create standard texts to describe a process step� Describe capacities and demonstrate their maintenance

Business ExampleAs the engineer/planner responsible for maintaining work centers, you must beaware of the structural design of the objects in SAP ERP. Work centers will onlybe created periodically after the initial go live of your implementation. In doingso, you need learn how the basic data and defaults will affect the modeling of yourmanufacturing process in the task list. You will also have to maintain the capacityand scheduling related data for work centers to integrate them properly.

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


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Figure 91: Work Center

Work centers determine the place where the operation is to be executed. Theycontain:

� Default values that are copied or referenced in operations when you createroutings

� Costing data that enables the costing of operations� Scheduling and capacity data required for lead time scheduling and capacity

planning

Figure 92: Work Center Data


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A work center contains several groups of data that you can enter on variousscreens (tab pages).

Default values are copied to the routing. You use the reference indicator to specifywhether a default value can be changed in the routing.

Standard Value KeyStandard values represent the times to be measured when the work center is usedon a task list, for example, machine time, labor time, and setup time.

Figure 93: Standard Value Key

These times are grouped together using a standard value key. This key determineswhich standard values are displayed for the work center.

The standard value key is entered on the work center Basic data tab. The key canbe set to required or optional within the work center.

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


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Figure 94: Default Values in Work Centers

Note: When setting up an SAP R/3 PP system, you should make sure thatas much data as possible is defined in work center maintenance.

The default values are copied to routings or production orders. This data is savedpartly in various screens in the work center. Activity types are proposed from thecost center assignment screen.

Figure 95: Standard Text for Operation Description

Standard texts for operation descriptions can be predefined in SAP R/3. Tomaintain standard texts, choose Routings→ Extras→ Standard text.


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A standard text key identifies the standard text. You can specify this key in thework center. When you use the work center in a routing, the standard text is copiedor referenced in the operation.

Work Center CapacityA major function of work centers is to support capacity planning and scheduling.In order to plan these functions, the available capacity must be maintained inthe work center.

Figure 96: Capacity Categories for a Work Center in SAP ERP

Capacity refers to the ability of a work center to perform a specific task. Youdistinguish between various capacities in a work center, such as labor or machines,by using the capacity category. To plan capacities in more detail, you can defineindividual capacities for each capacity, for instance in the capacity categoryPerson 3 employees or in the capacity category machine 5 lathes. Capacities canbe entered and changed in work centers, but can also be maintained independently.The system distinguishes between:

� Work center capacities� Pooled capacities� Reference capacities� Default capacities


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Figure 97: Capacity Header

Each work center can have one or more capacity headers to describe any limit tothe work it can perform in regards to time. For capacity headers to function, theymust be assigned as time to a work center. The capacity header will contain all thenecessary information to identify the available capacity for a constraint.

� Scheduling: Operating times and formulas are entered in the work center, sothat the duration of an operation can be calculated.

� Capacity planning: The available capacity and formulas for calculatingcapacity requirements are entered in the work center.

Work Center Scheduling ParametersShift sequences and shift definitions can be used for detailed maintenance of theavailable capacity for each capacity category only if you use intervals.

Shift sequences and shift definitions can be created and selected for special areasin Customizing with the help of the grouping key.


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Figure 98: Available Capacity Maintenance Using Central Shift Sequences

You define the work start, work finish, and break times for all work centers in ashift definition. In shift sequences, you maintain the sequence of individual shiftdefinitions for all shift sequences.

Figure 99: Scheduling Data at a Work Center


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The move time can be maintained separately. You can maintain a minimum movetime and a normal move time in the Interoperation times section of the Operationdetail screen. If reduction measures are necessary, the system uses the minimummove time for scheduling.

Note: The system uses the move time matrix to determine move timesonly if you have not entered any move times in the Interoperation timessection of the Operation detail screen.

As a rule, however, the transport time should be determined by means of thelocation groups from the sequential work centers and the move time matrix inCustomizing.

You can group work centers that are close together in a location group. Youmaintain location groups in Customizing. In the scheduling data screen for thework center, you assign the work center to a location group.

In the move time matrix, you can maintain the planned move times within alocation group or between two location groups and several plants.

You can maintain the queue time in the work center and in the routing operation.However, the system uses the queue time from the work center for schedulingonly if you have not maintained a queue time in the operation. If reductionmeasures are necessary, the value is reduced from the normal queue time to theminimum queue time.


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Exercise 9: Create a Work Center

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create and change a work center

Business ExampleTwo new machines have been purchased to support the assembly process forthe new pump. You are responsible for the definition of a new work center thatrepresents the two new machines.

Task 1:Create work center CENTER## in plant 1000. The work center is intended fortwo identical new machines with the work center category 0003.

1. Create work center CENTER## in plant 1000.

Hint: To maintain the individual tab pages (screen sequences),select Next screen.

2. Enter the following on the Basic data tab page:

Field EntryDescription Pump assembly ##

Personresponsible

0##

Usage 009 (All task list types)

Standard valuekey

SAP1 (Normal production)

Rules formaintenance Setup time - should be entered

Machine time - must be entered

Labor time - is not checked

Performanceefficiency ratekey

Machine - 090 %



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3. On the Default values tab page, choose the control key (between PP01 andPP99) and minutes as the unit of measure. Set the reference indicator forthe control key.

Note: Choose a control key from the PP series (PP01 to PP99). Itmust allow scheduling, capacity planning, and costing. It must alsoprint time tickets and allow confirmations.

Task 2:Answer the following questions about the work center that you have just saved.

1. Can you define operations using this work center without entering a setuptime?

2. Can you use a work center in which only the Basic data and Default Valuestab pages have been defined in routing operations?

Task 3:Add data for capacity, scheduling, and costing to the work center CENTER##.To do so, use the change transaction.

1. Enter the capacity category 001, Setup Formula SAP005, ProcessingFormula SAP006. On theChange Work Center Capacity: Header screen,adjust the capacity data using the following capacity data:

Field EntryCapacity planner group 0##

Grouping 51

Factory Calendar ID 01Active Version 1Base unit of measure Hour



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Field EntryStart/finish time 08:00 / 17:00

Length of breaks 1 hour

Capacity utilization 80 %

Number of individual capacities 2 machines

2. Maintain the Scheduling tab page with the following data:

Field EntryScheduling basis: Capacity category 001

Setup formula SAP001

Processing formula SAP002

Location group 0002

Standard queue time 2 hours

3. Maintain the following data on the Costing tab page:

Field EntryCost center 4230

Activity type Setup time -1422

Machine time -1420

Formula keys Setup - SAP005

Machine - SAP006


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Solution 9: Create a Work CenterTask 1:Create work center CENTER## in plant 1000. The work center is intended fortwo identical new machines with the work center category 0003.

1. Create work center CENTER## in plant 1000.

Hint: To maintain the individual tab pages (screen sequences),select Next screen.

a) Choose Logistics→ Production→ Master Data→ Work Centers→Work Center→ Create.

b) Enter plant 1000, work center number CENTER##, and work centercategory 0003.

c) Choose Enter .

2. Enter the following on the Basic data tab page:

Field EntryDescription Pump assembly ##

Personresponsible

0##




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Field EntryStandard valuekey

SAP1 (Normal production)

Rules formaintenance Setup time - should be entered

Machine time - must be entered

Labor time - is not checked

Performanceefficiency ratekey

Machine - 090 %

a) Maintain data from the above table. Confirm entries with Enter.

Hint: After the work center number, enter the work centerdescription, Pump assembly ##. Use the input help toenter the person responsible, usage, and standard value key.

Caution: Do not save or exit the work center at this time.

3. On the Default values tab page, choose the control key (between PP01 andPP99) and minutes as the unit of measure. Set the reference indicator forthe control key.

Note: Choose a control key from the PP series (PP01 to PP99). Itmust allow scheduling, capacity planning, and costing. It must alsoprint time tickets and allow confirmations.

a) Select Next screen or choose the Default Values tab.

b) Maintain the following data on the Default values tab page:

Field EntryControl key PP01 to PP99Unit of measure forstandard values

Minute

Reference indicator Set for the control key

c) Save the work center by choosing .



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Task 2:Answer the following questions about the work center that you have just saved.

1. Can you define operations using this work center without entering a setuptime?

Answer: Yes, but a warning message appears that prompts you to enter asetup time.

2. Can you use a work center in which only the Basic data and Default Valuestab pages have been defined in routing operations?

Answer: In the routing, yes. In the production order, no.

Task 3:Add data for capacity, scheduling, and costing to the work center CENTER##.To do so, use the change transaction.

1. Enter the capacity category 001, Setup Formula SAP005, ProcessingFormula SAP006. On theChange Work Center Capacity: Header screen,adjust the capacity data using the following capacity data:

Field EntryCapacity planner group 0##

Grouping 51

Factory Calendar ID 01Active Version 1Base unit of measure Hour

Start/finish time 08:00 / 17:00



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Field EntryLength of breaks 1 hour

Capacity utilization 80 %

Number of individual capacities 2 machines

a) Choose Logistics→ Production→ Master Data→ Work Centers→Work Center→ Change.

Choose Enter and select the Capacities tab.

b) Enter Capacity category 001 , Setup Formula SAP005, andProcessing Formula SAP006.

c) To access the capacity header data, double-click the number of thecapacity category or choose the Capacity header data button.

d) Enter data from the above table and choose Enter .

e) Arrow back to the Change work center: Capacity Overviewscreen.





Location group 0002

Standard queue time 2 hours

a) Enter data from the above table and confirm with Enter .




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Machine time -1420


Machine - SAP006

a) Select the Costing tab.

b) Make the required entries from the table above.

c) Save your work center by choosing .


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Lesson Summary

You should now be able to:� Describe the purpose of the standard value key and standard values� Describe the purpose of defaults in the work center� Create standard texts to describe a process step� Describe capacities and demonstrate their maintenance


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Lesson: Capacities in the Work Center

Lesson OverviewIn this lesson, we will discuss pooled and reference capacities.


� Describe the function of a pooled work center� Describe a reference work center� Use reference and pooled capacities

Business ExampleAs the production planner, you are responsible for maintaining capacity andscheduling-related data for the modeling of the manufacturing process. Thereis currently a labor pool that is shared among many work centers. This will bemodeled as a pooled capacity.

Many work centers also operate the same hours. To make maintaining theseworking hours more efficient, you want to use a reference capacity.

Pooled CapacitiesCapacity refers to the ability of a work center to perform a specific task.Capacities are differentiated according to capacity category. They are arrangedhierarchically under a work center. Capacity can be specific to a given workcenter, it can represent a group of people or machines, or it can be used as masterdata for many work centers.


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PLM114 Lesson: Capacities in the Work Center

Figure 100: Pooled Capacities

In SAP R/3, capacity data can be a stand-alone piece of master data called acapacity header. Each work center can have one or more capacity headers todescribe any limit to the work it can perform in regards to time. For capacityheaders to function, they must be assigned at some time to a work center. In SAPR/3, capacities are created without reference to a work center when modeling areference capacity or a pooled capacity.

A pooled capacity is used to model manufacturing resources that will be sharedby many work centers. For modeling purposes, this only makes sense if the poolof resources is actually a capacity constraint. Example, you have five productionlines that each require an operator for the entire duration that machine runs.However, you only have four operators in you resource pool. Therefore, onlyfour machines can run at any one time.

In SAP R/3, capacity headers can be modeled independently of work centers tosupport a shared/pooled resource. In the definition of the work center, the pooledcapacity will be referenced by the work center to act as a planning constraintduring capacity planning.

Reference CapacitiesOften times in repetitive, high-speed, manufacturing environments, companiesdivide similar manufacturing activities into manufacturing areas, or departments.Often times, these departments operate at the same starting and finishing times.To properly schedule any logistics activities, users must create and maintainthe necessary capacity data. However, if the data that is used to model certainresources is identical, than methods to ease data maintenance should be used.


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Figure 101: Reference Capacity

To ensure proper scheduling, each work center in SAP R/3 is typically maintainedwith its available capacity so that you know when the work center is open andclosed for business. By creating reference capacities, users can maintain oneset of capacities that applies to several work centers independently by linkingthe capacity data to each relevant work center. When it is necessary to updatethe capacity, the planner only needs to maintain the reference resource. Theinformation is relevant for all resources that have been linked by the referencefunction.

The first step in creating a reference resource is to create the capacity header.The capacity header for the reference capacity is no different then a work centercapacity header. Unlike the pooled capacity, there is no field to indicate that ithas a special function.

Once a capacity header has been created, users must reference it to the samecapacity category in the work centers. In the details of the capacity header, chooseExtras→ Reference avail. cap. This must be [performed on every work centerthat will use the capacity header as reference data.

Once the work center capacity category has been referenced, it can no longer bemaintained. The capacity data can only be maintained by editing the referencecapacity header.


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Exercise 10: Capacities in the Work Center

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create pooled capacities� Create a reference capacity� Assign the pool and reference to a work center

Business ExampleAs a general rule, all assembly areas will work the same hours: 7:30 am to 3:30PM. To eliminate redundant data maintenance, you want to use a referencecapacity to model this.

The assembly machines are run by a pool of six people who move from machineto machine to assure things are running smoothly.

Task 1: Create Reference ResourceYour assembly lines run from 7:30am to 3:30pm. Each line is available 95% of thetime, due to preventive maintenance. Create a reference capacity to model this.

1. Create a machine capacity, REF - ##, Assembly Lines, that will reflect themaster data above, and model you high-speed filling line master data.

Task 2: Pooled Capacity in mySAP SCMYou are staffed with six operators to run the assembly lines. Model these as apooled capacity.

1. Create a pooled capacity, Pool - ##, that will represent the labor force thatis responsible for running the assembly lines in plant 1000, based on thefigures above.

Task 3: Create a Work CenterCreate work center Assy-## in plant 1000. The work center will use the referencecapacity REF-## and pooled capacity Pool-##.

1. Create work center Assy-## in plant 1000.

2. Enter the following data on the Basic data tab page:



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Field EntryDescription Assembly line ##

Person responsible 0##


Standard value key SAP1 (Normal production)

Rules for maintenance Setup time - no checking

Machine time - no checking

Labor time - no checking

Performance efficiencyrate key

<blank>

3. On the Default values tab page, choose the control key and minutes as theunit of measure.

4. Add the reference capacity REF-##. Enter the capacity category 001, SetupFormula SAP005, and Processing Formula SAP006.








Machine time -1420


Machine - SAP006


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Solution 10: Capacities in the Work CenterTask 1: Create Reference ResourceYour assembly lines run from 7:30am to 3:30pm. Each line is available 95% of thetime, due to preventive maintenance. Create a reference capacity to model this.

1. Create a machine capacity, REF - ##, Assembly Lines, that will reflect themaster data above, and model you high-speed filling line master data.

a) Choose Logistics→ Production→ Master Data→ Work Centers→Capacity→ Create.

b) Enter the following data:

Field EntryPlant 1000

Capacity REF - ##

Capacity Category 001 - Machine

Select Header data (enter) .

c) Enter the following data in the capacity header:

Field EntryCapacity Description Assembly Lines

Capacity planner grp 2##

Pooled capacity deselect

Grouping 99 - APO

Factory calendar ID US

Active version 01 - Normal Capacity

Base unit of meas. H - Hours

Start 07:30:00

Finish 15:30:00

Length of breaks 00:00:00

Capacity Utilization 95

No. indiv. cap. 1

Relevant to finite scheduling Select

Can be used by several operations Deselect



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d) Choose Save .

Task 2: Pooled Capacity in mySAP SCMYou are staffed with six operators to run the assembly lines. Model these as apooled capacity.

1. Create a pooled capacity, Pool - ##, that will represent the labor force thatis responsible for running the assembly lines in plant 1000, based on thefigures above.

a) Choose Logistics→ Production→ Master Data→ Work Centers→Capacity→ Create.

b) Enter the following data:


Capacity Pool - ##

Capacity Category 002 - Labor

Select Header data (enter) .

Field EntryDescription GR ## Operators

Capacity Planner grp 2##

Pooled capacity Select

Grouping 99 - APO

Factory Calendar ID US

Active Version 01 - Normal AvailCapacity

Base unit of meas. H - Hour

Start 07:30:00

Finish 15:30:00

Length of breaks 01:00:00

Capacity Utilization 100

No. of indiv. cap 6

Relevant to finite sched. Select

Can be used by several operations Select



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c) Choose Save .

Task 3: Create a Work CenterCreate work center Assy-## in plant 1000. The work center will use the referencecapacity REF-## and pooled capacity Pool-##.

1. Create work center Assy-## in plant 1000.

a) Choose Logistics→ Production→ Master Data→ Work Centers→Work Center→ Create.

b) Enter plant 1000, work center number Assy-##, and work centercategory 0003.

c) Choose Enter .

2. Enter the following data on the Basic data tab page:

Field EntryDescription Assembly line ##

Person responsible 0##


Standard value key SAP1 (Normal production)

Rules for maintenance Setup time - no checking

Machine time - no checking

Labor time - no checking

Performance efficiencyrate key

<blank>

a) Confirm entries with Enter.

Hint: After the work center number, enter the work centerdescription Assembly line ##. Use the input help to enterthe person responsible, usage, and standard value key.

Caution: Do not save or exit the work center at this time.



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3. On the Default values tab page, choose the control key and minutes as theunit of measure.

a) Choose Next screen or choose the Default Values tab.

b) Maintain the following data on the Default Values tab page:

Field EntryControl key PP01

Unit of measure forstandard values

Minute



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4. Add the reference capacity REF-##. Enter the capacity category 001, SetupFormula SAP005, and Processing Formula SAP006.

a) Select the Capacities tab.

b) Enter Capacity category 001, Setup Formula SAP005, and ProcessingFormula SAP006.

c) To access the capacity header data, double-click the number of thecapacity category, or choose the Capacity header data button.

d) Choose: Extras→ Reference avail cap.

Enter the following:


Capacity REF-##

Capacity Category 001

Choose Enter .

Note: Notice that the fields cannot be changed since they arefrom the reference capacity.

e) Arrow back to the Change work center: Capacity Overview screen.

f) Choose Create capacity .

Enter the following and confirm with Enter:

Field EntryCapacity category 002

Pooled capacity Pool-##

Setup Formula SAP005





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a) Confirm with Enter .




Machine time -1420


Machine - SAP006

a) Select the Costing tab.

b) Make the required entries from the table above.

c) Save your work center by choosing Save .


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Lesson Summary

You should now be able to:� Describe the function of a pooled work center� Describe a reference work center� Use reference and pooled capacities


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Lesson: Integrating Costing with the Work Center

Lesson OverviewIn this lesson we will describe the integration between costing and the work center.


� Describe the how the work center integrates with costing� Demonstrate how the work center and the task list interact with the cost center

Business ExampleAs the engineer/planner responsible for maintaining work centers, you mustbe aware of the integration between the work center, the task list, and the costcenter. Work centers will only be created periodically after the initial go live ofyour implementation. You need learn how the initial setup parameters will becontinually integrated with the cost accounting module of SAP ERP.

Cost Center Assignment and IntegrationFor operation costing, it is necessary to assign the work center to a cost center.Additionally, activity types with cost unit rates are required because multiple workcenters can belong to one cost center.

Figure 102: Production Costing

You can assign a work center to only one cost center in a time period. A costcenter, however, can contain several work centers.


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PLM114 Lesson: Integrating Costing with the Work Center

You must enter the cost center activity types that are relevant to costing in a workcenter. There must be an activity type master for the activity types used.

The activity types maintained in the work center are used as default values for theoperation. If no reference indicator has been set for the activity type in the workcenter, you can change the activity type in the operation.


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Lesson Summary

You should now be able to:� Describe the how the work center integrates with costing� Demonstrate how the work center and the task list interact with the cost center


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PLM114 Lesson: Configuring the Work Center

Lesson: Configuring the Work Center

Lesson OverviewIn this lesson you will learn about the work center category, the field selectioncontrol, and the default work center.

You will also learn how to configure scheduling, including the formulas, standardvalue keys, and the corresponding check tables.


� Define default values for work centers� Explain the configuration settings regarding work centers� Create and test work center formulas

Business ExampleYour company has set some requirements that certain fields in the work center bemade required entries in order to save a work center. As the project team memberresponsible for implementing work centers in SAP ERP, r. you must becomefamiliar with how to configure the work center.

Work Center CategoryThe work center category is the central control element for work centermaintenance.


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Figure 103: Configuring Work Centers: Work Center Category

You use the task list application to define which departments can use the workcenter.

If you activate creation of change documents, you can trace changes to the workcenter.

You can assign a user status profile to the work center category. To maintain auser status profile, use transaction BS02.

You can also use the work center category to control the color in which a workcenter is shown in a hierarchy graphic.

Field selection control lets you define, field-by-field, which fields are ready forinput, display only, highlighted, or hidden.

The order of the screens can be specified for each work center category by usingscreen sequence control.

The default work center makes work center maintenance easier and can bedefined per plant and work center category.

Work Center Configuration: Default Work CenterYou can create a default work center for each plant and work center category.


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Figure 104: Configuring Work Centers: Default Work Center

If you create a work center without a template, and a default work center exists,the default work center is used. All screens are blank if no default work center hasbeen created for the work center category and plant.

If you create a work center with a copy template, the default work center isirrelevant.

Work Center Configuration: Screen ControlYou can define a separate screen sequence for each work center category. Severalwork center categories can use the same screen sequence.

Figure 105: Configuring Work Centers: Screen Control

The screen sequence controls which views are to appear in which order, and whichviews are required for checking the routing.

The screen sequence always starts with the basic data. The basic data is alwaysmandatory.

All other screens can be selected as and when required, can be numbered andsorted in any order, and can be mandatory if you so decide.


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The structure of screens (for example, the subscreens) cannot be influenced byCustomizing (as is possible for the material master record).

Note: Mandatory data: This indicator is relevant to the check work centerfunction in work center maintenance only. If you have not yet processed ascreen of the work center and execute the Check work center function,you see one of the following messages:

�Data is still to be maintained�, if the indicator for the screen is set.

�Data should still be maintained�, if the indicator for the screen is not set.

Work Center Configuration: Field ControlYou can define a separate field control for each work center category. Severalwork center categories can use the same field selection.

Figure 106: Configuring Work Centers: Field Selection Control

The field control is defined for each screen of the work center.

For each screen, you see the fields for which you can set the display.

You can define the setting for each field as general, meaning the same for allwork center categories. You can also define this specifically for one work centercategory, meaning . for one type of field selection.

You can produce a list of the settings for each field.


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You can define the following settings for a field:

� Hide completely� Display only (here, for example, fix the field contents by forcing a value

from the default work center)� Ready for input� Ready for input and required� In addition, you can highlight the field

Control KeyThe control key is the central control element of the process.

Figure 107: Control Key

The control key is a required field for the process. The control key can originatefrom the work center, either as a reference or as a proposal.


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You use the control key to define whether an operation (also suboperation, activityelement, phase, or secondary resource):

� Is read in scheduling� Is read in capacity planning� Is read in worklists in quality management (inspection characteristics)� Is read in costing� Automatically posts a goods receipt if a confirmation is entered for this

operation� Prints related shop floor papers (Print indicator), where this is defined for the

order type, plant, and MRP controller, and where the control key is checkedwhen printing shop floor papers:

� Prints time tickets ( Print indicator must be set first)� Prints confirmation slips ( Print indicator must be set first)

� Is processed externally

� <blank> = internally processed� �+� = externally processed� �X� = internally processed / can be processed externally

� Can be considered in scheduling (indicator Sched. external op.)� Supports confirmation:

� <blank> = possible, but not required� 1 = milestone confirmation� 2 = required� 3 = impossible


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Standard Value Key

Figure 108: Standard Value Key

Step 1: Check the parameters defined. For standard value keys, only parameterswith the original two standard values of operation can be used.

Step 2: Define the standard value key. You use this to define how many ofthe maximum of six standard values are used. By assigning parameters to theindividual elements of the standard value keys, you define the meaning of theindividual standard values, including dimension, unit of measure, format, anddescription.


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Configuration of Scheduling Including Formulas

Figure 109: Execution Time

The standard values defined for the routing and the formulas defined in the workcenter are used in lead-time scheduling to calculate the execution time for theindividual segments (setup, processing, and teardown).

If splitting takes place, you must also take into account the formula parameters inthe formula for the number of splits.

Figure 110: Formulas


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Formulas can be assigned to each capacity in the work center to calculate thecapacity requirement. At the same time, formulas can also be permitted fordifferent functions (capacity requirement, scheduling, and costing).

Generation controls the immediate code generation for the formula. If no code isgenerated in formula maintenance, it is generated at execution time.

There is a maximum of three lines per formula. Possible arithmetical operationsare +, -, *, /, SIN, COS, DIV, MOD, SQRT, EXP, and LOG.

Conversion of units of measure takes place automatically.

Figure 111: Setting Up Formulas


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Formula parameters are differentiated according to their origin. The followingorigins for a formula parameter can be defined in Customizing:

� General operation value: The parameter is linked to a field in the generaloperation data. The value of this field is entered in the formula. Typicalfields are lot size, base quantity, number of splits (partial lots), and numberof employees.

� Work center constant: The parameter is assigned a constant value in thework center. This value is used in the formula.

� Standard value: Using the standard value key, you can assign a standardvalue that is used as a parameter in the formula.

� User field in the operation: The value of a custom field in the operation isassigned to the parameter.

� Value from PRT assignment: This could be either the quantity or the usagevalue of the production resource/tool (PRT). This parameter can only be usedfor formulas that are used for PRT management.

� PRT constant: You assign a constant value to this parameter in the PRTmaster record. These formula parameters can only be used in formulas forPRT management.

� General formula constant: A value is assigned to this parameter, which isthen used in the application.

Capacity Categories and Capacities, Including ShiftSequences

Figure 112: Capacity Categories and Capacities

� Creating capacities� Assigning capacities to a work center, including intervals of available

capacity, shift sequences, shifts, and so on


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Figure 113: Shift Sequences

The data in the environment for defining shift sequences can be grouped. Thishelps structuring and selection.

1. Create the work break schedules. Work break schedules can contain severalbreaks. A break is a time interval at a fixed time or at a time relative to thestart of the shift, which is defined later.

2. Define the individual shifts. A shift is a fixed time interval. You can assign awork break schedule to a shift. From this time interval and the breaks withinthe assigned work break schedule, the working time is calculated.

3. Define the shift sequences. A shift sequence can consist of several lines (shiftnumbers). For each line, you can assign a shift from step 2 to each weekday.


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Other Check Tables

Figure 114: Other Check Tables

These check tables are found in Customizing, and some of them can also be foundalso in the work center menu by choosing Environment→ Current settings.

Suitability and wage group are parameters from human resources. These aredefined here if you do not use the SAP solution for human resources.


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Exercise 11: Optional: Work CenterFormulas

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create and test formulas

Business ExampleAs a member of the project team, you are responsible for feasible and exactscheduling of the company�s products

You first need to set up formulas.

Task 1:Create a formula for periodically repeating setup at a work center. To be able tocreate and test the formula, it is necessary not just to define the formula parametersfor the formula, but also to define a standard value key that supplies the formulawith values.

1. First define a formula parameter for the additional setup time and a formulaparameter for the period, expressed as a quantity, after which the setup isto be repeated. The parameter values should have their origin in a standardvalue in the operation.

Data for the group parameters:

Periodic Setup SintervalParameter SAP1## SAP2##Parameter Text Perd. Set-up SintervalKeyword PS group ## SI group ##Dimension Time (TIME) Without dimensions

(AAADL)Standard value 1Standard value unit Minutes (MIN) Piece(PC)

2. Define a formula for periodic setup at your work center. Call the formulaSAP1## with the description PS group ##. This formula must be valid onlyfor scheduling and must be generated immediately when you save. Use theparameters from the table for this.



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The formula isMachine * Operation quantity / Base quantity + Periodicsetup * ( (Operation quantity � 1 ) / Setup interval ).

3. Define a new standard value key so that the parameters in the formula can besupplied with values. The standard value key should allow entries for setuptime, machine time, and additional setup after 50 pieces. The key name isS## with the description SI group ##.

Task 2:Test the formulas on the scheduling screen of a new work center.

1. Create a new work center, PL##, with work center category PL##. Copythe Basic data, Default values, Capacities, and Scheduling screens fromwork center 1905. The description of the work center is Formula test ##.Save the work center.

2. Replace the processing formula key for execution time with the formulakey SAP1## that you created. Note the warning messages after you haveconfirmed the entry.

3. In the previous step, you saw a warning message, and you now want torespond to this. Make the relevant change in your work center.

4. Now test your formula on the Scheduling screen. Enter the following values:

Field EntryOperation quantity 101 pieces

Setup time 10 minutes

Machine time 1 minute

PS group ## 5 minutes

SI group ## 50 pieces


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Solution 11: Optional: Work CenterFormulasTask 1:Create a formula for periodically repeating setup at a work center. To be able tocreate and test the formula, it is necessary not just to define the formula parametersfor the formula, but also to define a standard value key that supplies the formulawith values.

1. First define a formula parameter for the additional setup time and a formulaparameter for the period, expressed as a quantity, after which the setup isto be repeated. The parameter values should have their origin in a standardvalue in the operation.

Data for the group parameters:

Periodic Setup SintervalParameter SAP1## SAP2##Parameter Text Perd. Set-up SintervalKeyword PS group ## SI group ##Dimension Time (TIME) Without dimensions

(AAADL)Standard value 1Standard value unit Minutes (MIN) Piece(PC)

a) In Customizing, choose Production→ Basic data→ Work center→General data→ Standard value→ Define parameters.

b) Choose the New Entries button.

c) Enter the parameters according to the table with origin key 2.

2. Define a formula for periodic setup at your work center. Call the formulaSAP1## with the description PS group ##. This formula must be valid onlyfor scheduling and must be generated immediately when you save. Use theparameters from the table for this.



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The formula isMachine * Operation quantity / Base quantity + Periodicsetup * ( (Operation quantity � 1 ) / Setup interval ).

a) In Customizing, choose Production→ Basic data→ Work center→Capacity planning→ Work center formulas→ Set up work centerformula definition.


c) Enter the Formula key SAP1## and Description PS–Group ##.

Hint:

� You determine the necessary parameter ID by means ofthe search field for parameters.

� Upper/lowercase and line breaks do not affect the formula.� Insert a blank before and after special characters

(operators).

d) Enter the formula SAP_02 * SAP_09 / SAP_08 + SAP1## *( ( SAP_09 - 1 ) DIV SAP2## ).

e) Set the Generate and Allowed for scheduling flags.

3. Define a new standard value key so that the parameters in the formula can besupplied with values. The standard value key should allow entries for setuptime, machine time, and additional setup after 50 pieces. The key name isS## with the description SI group ##.

a) In Customizing, choose Production→ Basic data→ Work center→General data→ Specify standard value key.


c) Enter the Standard value key S## and the Description SI Group ##.

Include the following parameters in the standard value key:

Field EntrySetup time SAP_01

Machine time SAP_02

PS group ## SAP1##

SI group ## SAP2##

d) Choose Save.



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Task 2:Test the formulas on the scheduling screen of a new work center.

1. Create a new work center, PL##, with work center category PL##. Copythe Basic data, Default values, Capacities, and Scheduling screens fromwork center 1905. The description of the work center is Formula test ##.Save the work center.

a) From the SAP Easy Access screen, choose Logistics→ Production→Master data→ Work centers→ Work center→ Create .



Work Center P-##

Work center category PL##

Reference plant 1000

Reference work center 1905

Choose Enter.

Ignore the warning message (different work center category).

=> Window �copy template�

Basic data, Defaults, Capacities and Scheduling

Copy = Enter

=> Basic data screen

Description: Formula test ##

=> Costing -> Cancel = F12 ( back to Basic data screen) & save

2. Replace the processing formula key for execution time with the formulakey SAP1## that you created. Note the warning messages after you haveconfirmed the entry.

a) Without leaving this screen, choose Work center→ Change.

b) Choose the Scheduling button.

c) Overwrite the key SAP003 with your formula key, SAP1xx.

d) Choose Enter.

You will receive warning messages.



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3. In the previous step, you saw a warning message, and you now want torespond to this. Make the relevant change in your work center.

a) Without leaving this screen, go to the Basic data tab page and overwritethe standard value key SAP1 with S##.

4. Now test your formula on the Scheduling screen. Enter the following values:

Field EntryOperation quantity 101 pieces

Setup time 10 minutes

Machine time 1 minute

PS group ## 5 minutes

SI group ## 50 pieces

a) Go back to the Scheduling tab page and choose the Test formula button.Enter the values from the exercise and choose Calculate.

b) The calculated overall execution time is 121 minutes, so setup wasrepeated twice.


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Exercise 12: Work Center Category andField Selection Control, Default WorkCenter (Optional)

Exercise ObjectivesAfter completing this exercise, you will be able to:� Set up a work center with a separate screen sequence� Set up a work center with a separate field sequence� Set up a work center category with a default work center

Business ExampleYou are responsible for the system settings for work centers. A new work centercategory is to be set up for work centers in discrete manufacturing.

Task 1:Create a new work center category for your area of responsibility.

1. Use work center category number PL## and the description Category ##.

2. Set up the work center category for the task list application Routings forproduction.

Task 2:Define a special screen sequence for work center category PL##.

1. For your work center category PL##, set the following screen selectionsequence: basic data, defaults, capacities, scheduling, costing, andtechnology. Apart from the basic data, no other views need to be required.

Task 3:Adapt the field selection control for work center category PL## on tab pages Basicdata and Capacities according to your requirements as follows:

1. Hide the Transition matrix field on the basic data tab page, and define thefield Person responsible as a required field.

2. Hide the Other formula and Internal distribution fields on the capacitiestab page.



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Task 4:Assign screen sequence and field selection to a work center category.

1. Assign the screen sequence and field selection you have created to yourwork center category PL##.

Task 5:Create a default work center in plant 1000 for the work center category PL##you defined in the first task.

1. Maintain the following data on the Basic data tab page:

Task list usage All task list typesStandard Value Key Normal production

2. Maintain the following data on the Default values tab page:

Control key Choose one of the PP series control keys (PP01,PP02 through PP99). It must allow scheduling,capacity planning, and costing. It must alsoprint time tickets and allow confirmations.

Units of measure forstandard values

Minute

3. Maintain capacity category machine on the Capacities tab page:

4. Create a work center in plant 1000 to check the settings for the screensequence and field selection.


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Solution 12: Work Center Category andField Selection Control, Default WorkCenter (Optional)Task 1:Create a new work center category for your area of responsibility.

1. Use work center category number PL## and the description Category ##.

a) In Customizing, choose Production→ Basic data→ Work center→General data→ Define work center category.

Choose New Entries.

Cat. PL##Description Category ##

Save.

2. Set up the work center category for the task list application Routings forproduction.

a) Select your new line and choose Application in the dialog structure.

Click New Entries for the selection of application P.

Choose Save.



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Task 2:Define a special screen sequence for work center category PL##.

1. For your work center category PL##, set the following screen selectionsequence: basic data, defaults, capacities, scheduling, costing, andtechnology. Apart from the basic data, no other views need to be required.

a) In Customizing, choose Production→ Basic data→ Work center→Set up work center screen sequence.

Make the following entries for work center category PL##:

2 Default values3 Capacities4 Scheduling5 Costing6 Technology

Delete the numbers of screens that are not required.

Choose Save.

Task 3:Adapt the field selection control for work center category PL## on tab pages Basicdata and Capacities according to your requirements as follows:

1. Hide the Transition matrix field on the basic data tab page, and define thefield Person responsible as a required field.

a) In Customizing, choose Production→ Basic data→ Work center→General data→ Define field selection.

Select the screen group Basic data and select influencing. Use yourwork center category PL## as the value for influencing, then makeabsolutely sure you choose Enter. Set the Transition matrix field tohide and the Person responsible field to required entry.



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2. Hide the Other formula and Internal distribution fields on the capacitiestab page.

a) Push-button Screen group

Select the screen group Capacity and select influencing. Use yourwork center category PL## as the value for influencing, then makeabsolutely sure you choose Enter button. Set the Other formula andInternal distribution fields to Hide.

Choose Save.

Task 4:Assign screen sequence and field selection to a work center category.

1. Assign the screen sequence and field selection you have created to yourwork center category PL##.

a) In Customizing choose, Production→ Basic data→ Work center→General data→ Define work center category.

Assign field selection PL## and screen sequence PL## to your workcenter category PL##.

Choose Save.

Task 5:Create a default work center in plant 1000 for the work center category PL##you defined in the first task.

1. Maintain the following data on the Basic data tab page:



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Task list usage All task list typesStandard Value Key Normal production

a) In Customizing, choose Production→ Basic data→ Work center→General data→ Define default work center.

Plant 1000Work center category PL##

Continue with Enter or push-button Basic Data (F5).

Task list usage 009Standard Value Key SAP1

Hint: In the field selection control for work center categoryPL##, you defined that the Person responsible field mustalways be maintained. The default work center is an exception,compared with ordinary work centers.

2. Maintain the following data on the Default values tab page:

Control key Choose one of the PP series control keys (PP01,PP02 through PP99). It must allow scheduling,capacity planning, and costing. It must alsoprint time tickets and allow confirmations.

Units of measure forstandard values

Minute

a) Switch to the Default values tab page. Control key, for example PP01.

3. Maintain capacity category machine on the Capacities tab page:

a) Switch to the Capacities tab page.

Capacity Category: 001

Choose Save.



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4. Create a work center in plant 1000 to check the settings for the screensequence and field selection.

a) From the SAP Easy Access screen, choose Logistics→ Production→Master data→ Work centers→ Work center→ Create.

Plant 1000Work Center <your choice>Work center category PL##

Choose Enter.

Note: Info message: �Values were set from the default workcenter.�

Person responsible is now mandatory.

b) Select the Capacities tab.

Note: The Internal Distribution and Other Formula fieldsare hidden.


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Lesson Summary

You should now be able to:� Define default values for work centers� Explain the configuration settings regarding work centers� Create and test work center formulas


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PLM114 Unit Summary

Unit SummaryYou should now be able to:� Describe the purpose and integration points of the task list (routing)� Describe the structure and purpose of the work center� Describe the purpose of the standard value key and standard values� Describe the purpose of defaults in the work center� Create standard texts to describe a process step� Describe capacities and demonstrate their maintenance� Describe the function of a pooled work center� Describe a reference work center� Use reference and pooled capacities� Describe the how the work center integrates with costing� Demonstrate how the work center and the task list interact with the cost center� Define default values for work centers� Explain the configuration settings regarding work centers� Create and test work center formulas


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Unit 6Task Lists

Unit OverviewThis unit introduces the basic concept of the SAP ERP task list (routing). You willbe instructed on the creation, maintenance, and configuration of the routing. Youwill also execute various transactions to manage the process surrounding its lifecycle. Several advanced functions will be covered in another lesson.


� Describe the different types of task lists� Describe the integration points of the task list� Assign manufactured items to routings� Allocate material components to operations� Maintain cutting measures of variable-size items� Describe the functions of suboperations� Retrieve additional fields in operations� Demonstrate how to make changes with history� Demonstrate how to use where-used lists and mass changes� Define system settings for routings

Unit ContentsLesson: Overview of the Task List .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282

Exercise 13: Create a Simple Routing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287Lesson: Creating a Routing and Material Assignment ... . . . . . . . . . . . . . . . . . .296

Exercise 14: Material Assignment and Component Allocation ... . . . .301Lesson: Suboperations and User-Defined Fields.. . . . . . . . . . . . . . . . . . . . . . . . . .307

Exercise 15: Suboperations for Material-Specific CapacityConstraints .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311

Lesson: Reporting and Mass Changes .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315Exercise 16: Task List Changes with ECM.... . . . . . . . . . . . . . . . . . . . . . . . . . .321

Lesson: Configuring the Routing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327


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Unit 6: Task Lists PLM114

Lesson: Overview of the Task List

Lesson OverviewIn this lesson, you will learn about task lists in SAP ERP. We will discuss thedifferent types of task lists and their integration points with other parts of theSAP ERP system.


� Describe the different types of task lists� Describe the integration points of the task list

Business ExampleAs the project lead for implementing task lists, you must be aware of the structuraldesign of the task list object in SAP ERP. In doing so, you need to learn how thetask list and work center are structured to integrate with several business areas inyour company. Your company has requirements to use task lists and work centersfor costing, engineering, and production.

Task Lists TypesA task list is a non-order-related process for implementing an activity. Task listsare used throughout the SAP ERP system to define a sequence of activities toproduce a specific result. Task lists are used in several application areas, includingPP, PP-PI, PS, QM, and PM. The following table shows several different types oftask lists that are used in the SAP ERP system.


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PLM114 Lesson: Overview of the Task List

Figure 115: Task List Types

Routings describe material-related production and are used in production planning.Reference operation sets are not created for a specific material, but can be used asreferences within routings or copied into routings. They are usually activities thatare common to many routings and can be created with either internal or externalnumbering. Rate routings describe material-related production using productionlines and are used mostly by repetitive manufacturing. Reference rate routings arenon-material specific activities that are common to many rate routings and can beused as references within rate routings or copied into them to simplify data entry.Master recipes describe material specific production and are used in productionplanning for process industries. Rough-cut capacity profiles are used to viewresource loads in sales and operations planning without BOM explosion. Networkscontain instructions on how to perform tasks in a specific way, in a specific order,and in a specific time period, and are used in project systems. Inspections plansdescribe the inspection process for a material and are used in quality management.

Structure of a RoutingA routing determines the sequence of individual operations that are necessaryto produce a product. It describes the sequence of activities, where the work isperformed, and how much of the work center's resources will be consumed. Arouting can be created with or without a material number. Routings withoutmaterial numbers can be used by many materials that all use the same productionprocess, production line, or manufacturing steps.

A routing is made up of operations to which work centers are assigned. The detailsof the operations contain the standard values or times of production at that workcenter. They also contain information about each work center where the work is to


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be performed. The SAP ERP system stores routings in groups that can be eitherinternally or externally assigned. There can be many routings in a group, eachdistinguished by a different group counter.

Other important assignments in the routing include the materials components fromthe BOM and any PRTs that are required for production. PRTs are items neededfor production that are not consumed like tools and fixtures.

More than one BOM can have components allocated to the same routing.Components are assigned to the specific operation where they are needed andconsumed in the production process.

Inspection characteristics can be assigned to the operations in the routing if aquality inspection is to be performed during an operation. Trigger points canalso be assigned to an operation to trigger functions when a certain event occurs.Examples of such events might be a change in status or the release of an operationbased on another event happening, such as a confirmation.

Figure 116: Routing Structure

Routing IntegrationA routing is independent of an order and is used in the creation of an order. Theoperations and information from the routing is copied into the order during ordercreation. This includes the planned time for each activity within an operation(standard value), the work center, and the control key.

The routing information in the order becomes the basis for lead time scheduling,product costing, and capacity planning.


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Figure 117: Routing Usage

A routing is defined at the plant level. This means that the organizational elementsfor company code, valuation area, and plant all need to be defined prior to creatinga routing. A work center is needed to assign to the operation, so a work centermust also exist before the routing can be created. The routing integrates withmaterial master data, BOM components, work centers, as well as product costing,capacity planning, production orders, procurement, and planning.

Figure 118: Routing Integration in SAP ERP


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Exercise 13: Create a Simple Routing

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create a simple routing for a material� Create a group routing that is not material specific

Business ExampleYour business is implementing SAP ERP and you must model the manufacturingprocedure for material manufacturing. You must create a routing for materialsproduction.

Task 1:Create a simple routing for material production.

1. Create a routing for the production of material T-B## in plant 1000 thatconsists of the four steps in the table below. The routing should be creationstatus, valid from today's date, for production usage, and for lot sizes from1 to 100,000 Pc. Use the data in the table below to complete the routinginformation.

Primary Operation Data

Opera-tion #

WorkCenter

ControlKey

Description

10 T-A## PP01 Lathe casing according to drawing20 T-B## PP01 Drill holes30 T-C## PP01 Insert Flat gasket40 T-C## PP01 Inspect and deliver to stock

Standard Processing Times

Activity Op 10 Op 20 Op 30 Op 40Setup 10 Min 3 Min 0 Min 0 MinMachine 30 Min 10 Min 0 Min 0 MinLabor 30 Min 10 Min 5 Min 10 Min

2. What are the task list group number and group counter on the header ofyour routing?



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3. What is the base quantity and operation unit for operation 10 and how does itrelate to the standard values?

4. Save your routing by choosing Save .

Task 2:Display your routing and answer the following questions.

1. Display your routing.

2. What are the group number and group counter?

3. When was the routing created and by whom?

4. What are the validity dates for the routing?

5. What are the validity dates of operation 20?

Task 3:Create a non-material-specific group routing to manufacture many different pumpsthat all have the same manufacturing process.

1. Create a non-material specific routing for the production of several differentpumps in plant 1000 thath all use the same five steps in the table below. Therouting should be creation status, valid from today's date, for productionusage, and for lot sizes from 1 to 100 only. Use the data in the table below tocomplete the routing information.


Opera-tion #

WorkCenter

ControlKey

Description

10 T-M## PP01 Material Staging20 T-E## PP01 Pre-assemble pump30 T-P## PP01 In-process inspection40 T-P## PP01 Final assembly50 T-P## PP99 Deliver to stock


Activity Op 10 Op20 Op 30 Op 40 Op 50Setup 10 Min 30 Min 0 Min 30 Min 0 MinMachine 0 Min 0 Min 0 Min 10 Min 0 MinLabor 0 Min 10 Min 5 Min 10 Min 10 Min



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Solution 13: Create a Simple RoutingTask 1:Create a simple routing for material production.

1. Create a routing for the production of material T-B## in plant 1000 thatconsists of the four steps in the table below. The routing should be creationstatus, valid from today's date, for production usage, and for lot sizes from1 to 100,000 Pc. Use the data in the table below to complete the routinginformation.


Opera-tion #

WorkCenter

ControlKey

Description

10 T-A## PP01 Lathe casing according to drawing20 T-B## PP01 Drill holes30 T-C## PP01 Insert Flat gasket40 T-C## PP01 Inspect and deliver to stock



a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Standard Routings→ Create or use transaction code CA01.

b) Enter the material T-B## and plant 1000 and choose Enter .

c) Enter Usage 1 for Production, Status 1 for Creation Phase,Planner group 0##, and lot size of 1 to 100,000 Pc.

d) Select the Operations Overview icon and enter the Primary OperationData from the table. Respond to any system messages that appear.

e) Select all operations and choose Details→ Operation from the menu.Enter the Standard Operation Processing Times from the table andchoose to navigate to the next operation detail screen. Continueuntil all times have been entered and then choose to return to theoperation overview.



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a) Choose to view the header. The group number should be blankand the group counter is 1.


a) From the operations overview, double-click on the operation number0010. You should now be in the details of the operation. The basequantity is 1 PC. The standard values are the setup and labor timesrequired to produce 1 casing.


a)



a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Standard Routings→ Display or use transaction codeCA03. Enter T-B## and plant 1000 and choose .


a) The group number will vary, but should be a number beginning with50000 and the group counter should still be 1.


a) In the header details, scroll to the bottom of the screen. In theadministrative data section, you will find today's date for the creationdate and your logon as the creator.


a) The validity dates should be from today to 12/31/9999 as found inthe administrative data section.


a) Select and double-click on operation number 20. Scroll to the bottomof the Operation details screen and you will see validity dates identicalto those on the header: from today's date to 12/31/9999.



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Task 3:Create a non-material-specific group routing to manufacture many different pumpsthat all have the same manufacturing process.

1. Create a non-material specific routing for the production of several differentpumps in plant 1000 thath all use the same five steps in the table below. Therouting should be creation status, valid from today's date, for productionusage, and for lot sizes from 1 to 100 only. Use the data in the table below tocomplete the routing information.


Opera-tion #

WorkCenter

ControlKey

Description

10 T-M## PP01 Material Staging20 T-E## PP01 Pre-assemble pump30 T-P## PP01 In-process inspection40 T-P## PP01 Final assembly50 T-P## PP99 Deliver to stock




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Activity Op 10 Op20 Op 30 Op 40 Op 50Setup 10 Min 30 Min 0 Min 30 Min 0 MinMachine 0 Min 0 Min 0 Min 10 Min 0 MinLabor 0 Min 10 Min 5 Min 10 Min 10 Min


b) Make sure the Material field is blank, enter plant 1000, enter PUMP##in the Group field, and choose Enter .

c) Enter Usage 1 for Production, Status 1 for Creation Phase,Planner group 0##, and lot size of 1 to 100,000 Pc.

d) Select Operations Overview and enter thePrimary Operation Data from the table. Respond to any systemmessages that appear.

e) Select all operations and choose Details→ Operations from the menu.Enter the Standard Operation Processing Times from the table andchoose to navigate to the next operation detail screen. Continueuntil all times have been entered and then choose to return to theoperation overview.


a) Choose to view the header. The group number should be PUMP##and the group counter is 1.


a) From the operations overview, double-click on the operation number0010. You should now be in the details of the operation. The basequantity is 1 PC. The standard values are the setup time requiredto produce 1 pump.


a)



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a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Standard Routings→ Display or use transaction codeCA03. Make sure the material field is blank and enter plant 1000,group PUMP##, and choose .


a) The group number should still be PUMP## and the group countershould still be 1.


a) In the header details, scroll to the bottom of the screen. In theadministrative data section you will find today's date for the creationdate and your logon as the creator.


a) The validity dates should be from today to 12/31/9999, as found inthe administrative data section.


a) Select and double-click on operation number 20. Scroll to the bottomof the operation details screen and you will see validity dates identicalto those on the header: from today's date to 12/31/9999.


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Lesson Summary

You should now be able to:� Describe the different types of task lists� Describe the integration points of the task list


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Lesson: Creating a Routing and Material Assignment

Lesson OverviewIn this lesson, you will learn how to assign materials to routings, allocate materialscomponents to specific operations on the routing, and to specify the dimensionsof variable-size components.


� Assign manufactured items to routings� Allocate material components to operations� Maintain cutting measures of variable-size items

Business ExampleAs a production planner you are responsible for the correct staging of materialcomponents for each operation in production. Therefore you have to assign thesecomponents to operations and, if necessary, adjust the BOMs.

Material AssignmentYou use this function to determine which material is to be produced with a routingor rate routing. On the basis of this assignment, the routing can be used for salesand operations planning, material requirements planning, creating productionorders and product costing for this material.

A material master record must exist in the system for the material that is to beproduced. It must have a material type that is allowed for assignment to a routingor rate routing.

Materials can be linked to routings for the following scenarios:


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PLM114 Lesson: Creating a Routing and Material Assignment

Figure 119: Multiple Products - One Routing

The same routing can be used to produce several different materials. Each producthas its own unique bill of material but is manufactured by a common set ofactivities with the same standard times. For example, both red and green chairscan be produced using the same routing.

The material and routing can belong to different plants, for example, the planningplant and the production plant may not be the same.

The material assignment can be done three different ways. You can create therouting for a specific material, use the material assignment functionality in therouting header, or you can use a production version.

If you create a routing for a specific material the material assignment isautomatically done by the system. No further settings are necessary and everyorder created finds this routing assignment and uses the appropriate routing tocreate the order. This process will be discussed further in the routing configurationlesson.

If you have created a non-material specific routing or a group routing you can usethe material assignment. In the header of the routing, the material assignmentbutton will show you a list of all materials that are assigned to use this routingfor their production. It allows you to assign more materials to the list. This isalso effective for using a routing created for one material to produce a differentmaterial. The assignment could be for a material in a different plant, which allowsyou to plan production in one plant and produce in another.


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The third option is to use a production version. A production version specifiesthe production technique that can be used to produce a material. It specifies theBOM and routing used for production with date and lot size validities. In this caseyou must also set the selection method field on the MRP4 view of the materialmaster to select by production version.

Component AllocationComponent allocation determines when materials are to be made available toproduction and consumed in your production process. The shop floor paperswill indicate the work center and time to deliver the component to the specificoperation to which it was assigned. As production is completed and confirmationsare recorded this allocation will also control the consumption of the components.

Figure 120: Material Assignment

The following data must already exist in the system:

� The operations in the routing.� The master record for the material to be produced.� The bill of material (BOM) for the material to be produced.

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


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You can

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

Material components in a BOM that are not assigned to an operation in the routingare automatically assigned (default) to the first operation when you create aproduction order.

Each item on the BOM can be assigned to only one operation. Items which havequantities of more than one and need to be assigned to more than one operationwill need to be adjusted in the BOM to allow this type of allocation. For example,BOM item 10 has 2 pieces one of which is used at operation 20 and the other atoperation 40. This will necessitate splitting BOM item 10 into 2 BOM items eachwith quantity of one, say item 10 and item 15. Then item 10 can be allocated tooperation 20 and item 15 can be allocated to operation 40.

According to the item category of the assigned components you can make furtherdecisions about their processing, for example, backflushing of stock items orcutting size of variable-size items (discussed in next section).

By repeating this process, you can assign material components from severalBOMs or alternative BOMs to the same routing . In this case, when you create aproduction order, you select the BOM and thus which material components areto be assigned in the production order. The system can do this automatically,depending on the system settings.

Variable-Size Item Calculations in the RoutingWhen you maintain the BOM, the final measurements are specified for thevariable-size items.

If you require a large cutting measure for the production of this BOM item,you can specify this when you assign the operation. Only those involved inmaterial staging get these measurements. Inventory management books out themeasurements from the BOM.


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Figure 121: Variable Size Items


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Exercise 14: Material Assignment andComponent Allocation

Exercise ObjectivesAfter completing this exercise, you will be able to:� Assign materials to routings� Assign material BOM components to specific operations on the routing� Enter dimensions for variable sized components

Business ExampleSeveral different models of pumps use the same manufacturing steps in productionand can use the same routing. You need to assign materials T-F1## and T-F2## toyour PUMP## group routing. To make the manufacturing process more efficient,you want to assign material components from the BOM to specific operations onthe routing to ensure they are delivered to the correct work center at the correcttime. One of your components is a variable sized item and needs to have thespecific dimensions defined.

Task 1:Display the material assignment of your T-B## routing.

1. Display the material assignment for your T-B## routing.

Task 2:Assign materials to your group routing.

1. Assign the materials T-F1## and T-F2## to your group routing PUMP##.

Task 3:Assign material components from the BOM to specific operations on the routing.

1. First, create a plant-specific BOM for T-B## in plant 1000. Use the BOMT-B1## as a template.

2. Assign material components from the BOM of T-B## to specific operationson the routing. Assign components T-T2## and T-T3## to operation 30.



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Task 4:Assign components to specific operations on your group routing.

1. Assign the material components from T-F1## to specific operations onyour group routing PUMP##. Assign components T-B1## and T-T3## tooperation 40, and T-B2##, T-B3##, and T-B4## to operation 20 of yourgroup routing PUMP##.


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Solution 14: Material Assignment andComponent AllocationTask 1:Display the material assignment of your T-B## routing.

1. Display the material assignment for your T-B## routing.

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Standard routings→ Display or use transaction codeCA03.

b) Enter material T-B##, plant 1000, and choose Enter .

c) Select the Header icon to go to the header details.

d) Choose the Material Assignment icon .

e) In the dialog box that appears, you will see your material, T-B##, plant1000, listed in the table as assigned to use this routing.

Task 2:Assign materials to your group routing.

1. Assign the materials T-F1## and T-F2## to your group routing PUMP##.

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Standard routings→ Change or use transaction codeCA02.

b) Leave material blank, enter plant 1000, group PUMP##, and chooseEnter .

c) Select the Header icon to go to the header details.

d) Choose the Material Assignment icon .

e) In the dialog box that appears, enter Group counter 1, materialT-F1##, and plant 1000 on the first line in the table.

f) Enter Group counter 1, material T-F2##, and plant 1000 on thesecond line in the table.

g) Choose Continue and both materials are assigned to use this routing.

h) Choose Save to save your routing and exit.



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Task 3:Assign material components from the BOM to specific operations on the routing.

1. First, create a plant-specific BOM for T-B## in plant 1000. Use the BOMT-B1## as a template.

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Create.


Field EntryMaterial T-B##

Plant 1000

Usage 1


b) Select the Copy from icon .

c) In the Copy From.. dialog box, enter the material T-B1##, plant1000, and BOM Usage 1 and choose Enter .

d) Select all of the components to copy and choose Copy again.

e) Save the BOM by choosing .

2. Assign material components from the BOM of T-B## to specific operationson the routing. Assign components T-T2## and T-T3## to operation 30.



c) Select the Component Allocation icon .

d) Select items T-T2## and T-T3## from the BOM that appears. Choose

the New Assignment icon .

e) You can enter operation 30 in the activity field or choose to selectthe operation from a list.

f) Choose Continue .

g) Choose Save to save your routing and exit.



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Task 4:Assign components to specific operations on your group routing.

1. Assign the material components from T-F1## to specific operations onyour group routing PUMP##. Assign components T-B1## and T-T3## tooperation 40, and T-B2##, T-B3##, and T-B4## to operation 20 of yourgroup routing PUMP##.


b) Leave material blank, enter plant 1000, group PUMP##, and chooseEnter .

c) Choose the Component Allocation icon .

d) A dialog box appears showing a list of all materials that are assignedto that routing. Choose T-F1## by clicking on the line in the tableand choose .

e) Select items T-B1## and T-T3## from the BOM that appears. Choose

the New Assignment icon .

f) You can enter operation 40 in the activity field, or choose

to select the operation from a list.

g) Choose Continue and repeat steps e through f to assign componentsT-B2##, T-B3##, and T-B4## to operation 20.


i) If you want, you can repeat the above procedure to make componentassignment for the T-F2## BOM to your PUMP## group routing.


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Lesson Summary

You should now be able to:� Assign manufactured items to routings� Allocate material components to operations� Maintain cutting measures of variable-size items


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PLM114 Lesson: Suboperations and User-Defined Fields

Lesson: Suboperations and User-Defined Fields

Lesson OverviewIn this lesson, you will learn how to use suboperations for more detailed planningand how user-defined fields can be used to add information to the routing andorder.


� Describe the functions of suboperations� Retrieve additional fields in operations

Business ExampleAs a production planner, you are responsible for routing management in theproject team. You would like to model more detailed capacity constraints inyour manufacturing process. You have several materials that require the use ofspecific tools during production. You would like to use suboperations to modelthese material specific constraints. You also need to use user-defined fields fortransferring data in the operation from other systems.

SuboperationsSuboperations are subordinate to an operation and used for more detailed planningof the process step that is described in the operation. They are typically used tocarry out more detailed planning for capacity or costing for an operation. Forexample, you can use suboperations to assign several people or machines thatare required at the same time, to an operation. A suboperation can be costed,but can only be scheduled relative to the superior operation. You can cumulatestandard values from suboperations on the corresponding operation. You candetermine whether suboperations belonging to an operation are copied into theproduction order.


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Figure 122: Suboperations

Suboperations are hierarchically structured under an operation and are used tocarry out more detailed capacity planning or costing. For example, suboperationsare used in a company at manufacturing centers.

In the figure, operation 20 is responsible for compliance with the productionschedule. suboperations 20/10 to 20/40 are used for exact capacity planning andcosting.

The control key has an important influence on this process. When usingsuboperations, it is important that you ensure costs and capacity requirementsare not calculated twice.

Figure 123: Scheduling Suboperations


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The dates of the suboperations are determined using the start or finish referencefor an operation when you specify an offset value.

The reference dates for the start and finish of a suboperation are:

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

If an operation is divided into suboperations, the standard values for thesuboperations can be cumulated under the main operation. If the suboperationsrun in parallel, this kind of cumulation is not possible because the cumulatedvalues would be too high.

Example: If you set a start reference for a suboperation to start processing with atime offset of 5- (5 minus) hours, processing in the suboperation will start 5 hoursbefore it does in the main operation.

An operation that is not to be carried out in the plant in the operation or routingcan be assigned to another plant. The plants only have to belong to the samecontrolling area. A suboperation can be assigned to another plant as its superioroperation. The unit of measure in the suboperation can differ from the one inthe operation.

You cannot assign material components, production resources/tools nor inspectioncharacteristics to suboperations, only to operations.

User Defined fields in the RoutingYou can use user-defined fields to assign data fields to an operation orsuboperation. You define the usage and meaning of these data fields yourself.You can enter business information or values for formula parameters that arenot included in the standard system.


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Figure 124: User-Defined Fields

Depending on the field key, up to twelve data fields with various field formatsare available. These are:

� Up to four general fields for any text You can use them to store informationabout people responsible, substitutes or telephone numbers, for example.

� Up to two quantity fields You can assign additional formula parameters tothe quantity fields in the field key. With the help of formula parameters youcan use the values of the quantity fields in work center formulas, to calculateprocessing times, capacity requirements and costs. In addition, there is also afield for the unit of each quantity field. Default values and their units whichyou have maintained in Customizing for formula parameters are transferred,but you can change this data. If you have entered data in the quantity fieldsand then change the field key, the old values remain unchanged.

� Up to two value fields � In addition there is also a field for the unit of eachvalue field.

� Up to two date fields � Here you can enter internal start dates, for instance.� Up to two check boxes � You can use these to indicate whether an operation

is to be included in evaluations in the Info System, for instance.

A field key is defined in Customizing for routings, in which the requiredcombination of user-defined fields is stored. By assigning a field key to anoperation or suboperation, you determine which user-defined fields are availablein the particular object and also which field names or key words are used for thesefields You can then enter data in these user-defined fields. Note that the systemdoes not check for data validity.


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Exercise 15: Suboperations forMaterial-Specific Capacity Constraints

Exercise ObjectivesAfter completing this exercise, you will be able to:� Model detailed capacity planning for an operation using suboperations� Create suboperations� Accumulate the standard values of the suboperations in the superior operation

Business ExampleOne of the operations in your production process consists of several steps that needto be planned in more detail for capacity. You want to use suboperations to do this.

Task 1:Use suboperations to model more detailed planning of operation steps.

1. In the production of T-B##, operation 20 has several steps that must becapacity planned in more detail. Create four suboperations to model thedetail capacity of this operation using the data in the table below.

Subop Description Setup Ma-chine

La-bor

RefDate toStart

Offsetto start

10 Setup 3Min

0 Min 0Min

01 0 Min

20 Mill Pump casing 0Min

15Min

15Min

02 0 Min

30 Turn pump casing 0Min

10Min

10Min

02 15 Min

40 Deburr pumpcasing

0Min

10Min

10Min

02 25 Min

Task 2:Accumulate the standard values of the suboperations in the superior operation.

1. In your routing for T-B##, first check the standard values in the superioroperation 20.

2. In your routing for T-B##, accumulate the standard values of thesub-operations in the superior operation 20.


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Solution 15: Suboperations forMaterial-Specific Capacity ConstraintsTask 1:Use suboperations to model more detailed planning of operation steps.

1. In the production of T-B##, operation 20 has several steps that must becapacity planned in more detail. Create four suboperations to model thedetail capacity of this operation using the data in the table below.

Subop Description Setup Ma-chine

La-bor

RefDate toStart

Offsetto start

10 Setup 3Min

0 Min 0Min

01 0 Min

20 Mill Pump casing 0Min

15Min

15Min

02 0 Min

30 Turn pump casing 0Min

10Min

10Min

02 15 Min

40 Deburr pumpcasing

0Min

10Min

10Min

02 25 Min



c) Overwrite operation number 0050 with 0020, then enter suboperationnumber 10, work center T-B##, and the description from the tableabove.

d) Select the suboperation and choose Details→ Operation to enter thestandard values and offset information. You may have to scroll downin the details to enter the offset.

e) Repeat this procedure for each suboperation and save your routing.



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Task 2:Accumulate the standard values of the suboperations in the superior operation.

1. In your routing for T-B##, first check the standard values in the superioroperation 20.



c) To check the standard values of the superior operation 20, select theoperation and choose Details→ Operation. Make note of the valuesfor Setup, Machine, and Labor.

2. In your routing for T-B##, accumulate the standard values of thesub-operations in the superior operation 20.



c) In the operation overview, select the superior operation 20.

d) Choose Extras→ Summarize standard values.

e) Now check the standard values of the superior operation 20 to see ifthey have been updated. Select operation 20 and choose Details→Operation. You will see that the standard values have been updatedfrom the accumulated totals of the suboperations.


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Lesson Summary

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


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PLM114 Lesson: Reporting and Mass Changes

Lesson: Reporting and Mass Changes

Lesson OverviewIn this lesson you will learn the reporting options for routings and how masschanges can be accomplished.


� Demonstrate how to make changes with history� Demonstrate how to use where-used lists and mass changes

Business ExampleIn the project team, you are responsible for the where-used lists and the masschanges in routing management. Your company must document the changes in itsroutings. You are responsible for ensuring changes are documented with history.

Change with a Change Master RecordChanges without history

Changes without history do not have to be documented because they takeplace during the development stage of the product, for example.The status of the object prior to the change is not saved. The systemdocuments the changes that have taken place but you can only find outindirectly about the status of the object before the change.

Changes with historyChanges with history must be documented because they take place duringproduction.Both the status before and after the change is saved. The system createschange documents. For some objects, these change documents differ fromthose created for changes without history.Engineering change management in the SAP system enables you to fullydocument changes. Some of these changes may be needed for productliability purposes, for example.


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Figure 125: Engineering Change Management

Engineering change management is a central logistics function that can be used tochange various types of master data and document the changes.

By using a valid-from date for the change master record, the changes become validon a predefined date. This aids long-term planning.

You can use engineering change management to store certain SAP objects (forexample, BOMs and routings) more than once. This means that you can store theobjects in all relevant change statuses.

The changes take effect automatically at the predefined time in all areas of thelogistics process chain, for example, sales order, material requirements planningand shop floor control.


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Figure 126: Why Use Engineering Change Management?

You can use engineering change management to group together changes todifferent SAP objects that are affected by one change. You can change all theobjects at the same time or you can define different change dates for individualobjects.

You can use engineering change management to help fulfill your legal obligationsregarding documentation of changes.

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

As of release 4.0, there are other types of parameter effectivity besides date, forexample, serial number, time interval, customer. These topics are discussed inmore detail in the PLM150 � Engineering Change Management course.

Reporting and Mass ChangesYou can use the overview variant to control the information in the list and theorder in which it is listed (for example, sequence, operation, component, PRT).You can create various displays for routings using object overviews. You candefine your own object overviews in configuration in the IMG.


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Figure 127: Reporting Variants

By generating where-used lists, you can display the routings which use particularwork centers, reference operation sets, reference rate routings, and productionresources/tools (PRTs). You may need this information if you want to delete awork center or reference operation set but you want to first check if it is being usedin a routing. If you want, you can also display routings which have already beendeleted online but which still exist in the database.

Figure 128: Where-Used Lists

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


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Figure 129: Mass Change and Reporting

If you want to replace an object in several routings with another object (forexample, an old work center with a new one) you can use the mass replacefunction. You do not have to generate a where-used list in order to replace eachwork center individually. Instead, you can use the mass replace function to quicklyand completely replace work centers in all routings where they are used.

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

� Work centers� PRTs� Reference operation sets

The system generates a list of all routings that use the object to be replaced.

When you use the mass replace function without a change number, the new objectswill have the same validity periods as the old objects.


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Figure 130: Mass Replacement of Routing Data

You can use the replace function to make mass changes to work centers, PRTs,and reference operation sets.


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Exercise 16: Task List Changes with ECM

Exercise ObjectivesAfter completing this exercise, you will be able to:� Make changes without history in a task list� Make changes with history in a task list� Display changes with history in a task list� Make mass changes with history in a task list

Business ExampleAs new work centers are created to update your production equipment, task listswill also need to be updated. This may require changes to be captured with historyfor legal or reporting purposes. These changes also may need to be made inmass for all routings.

Task 1:Display a list of all changes without history that have been made to your routing.

1. Display a list of changes that have been made to your routing, T-B##, thusfar.

Task 2:Check to see which routings and rate routings are using a specific work center.

1. Determine to which other task lists work center T-B## has been assigned byexecuting a work center where-used list.

Task 3:Because of a capacity constraint in your production, your company is building anew work center that will be operational in two months. Replace the final assemblywork center in your routing effective on that day and be sure to track history.

1. Replace the final assembly work center T-C## on your T-B## routing, withyour new work center CENTER## using your Engineering Change NumberECN## to track history.



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Task 4:Display your routing with different key dates to view the change history.

1. Display your routing with a key date one day before the change date (today +2 months - 1 day). Which work center is assigned to operation 40? What arethe validity dates of operation 40?

2. Display your routing using a key date of one day after the change date (today+ 2 months + 1 day). Which work center is assigned to operation 40? Whatare the validity dates of operation 40?

Task 5:Since the new work center will replace the old one on all routings, do a massreplace with history.

1. Your new work center, CENTER## , will replace work center T-F## on allroutings two months from today. Use mass replace and change numberECN## to track history.


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Solution 16: Task List Changes with ECMTask 1:Display a list of all changes without history that have been made to your routing.

1. Display a list of changes that have been made to your routing, T-B##, thusfar.

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Reporting→ Task List Changes or use transaction codeCA60.

b) Enter task list type N, material T-B##, and plant 1000. Accept thedefault dates, be sure that all changes in the list are selected, andchoose Execute .

c) This is the list of changes that have been made to your routing. Look atthe Changed on date and Changed by field.

Task 2:Check to see which routings and rate routings are using a specific work center.

1. Determine to which other task lists work center T-B## has been assigned byexecuting a work center where-used list.

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Reporting→ Where-Used List→ Work Center or usetransaction code CA80.

b) Enter the work center T-B## and plant 1000. Accept the default keydate, enter task list type N in the from field, S in the to field to check allroutings and rate routings, and choose Execute .

c) Choose an overview variant from the list that displays work centerslike L00000000060 and choose Enter. The system displays a list of allroutings and rate routings that have the work center assigned, as well asthe sequence and operation to which it is assigned.



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Task 3:Because of a capacity constraint in your production, your company is building anew work center that will be operational in two months. Replace the final assemblywork center in your routing effective on that day and be sure to track history.

1. Replace the final assembly work center T-C## on your T-B## routing, withyour new work center CENTER## using your Engineering Change NumberECN## to track history.

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Standard Routings→ Change or use transaction codeCA02.

b) Enter the material T-B##, plant 1000, change number ECN##, andchoose Enter .

c) A warning message appears in the status bar indicating, �The key dateis overwritten with the date from the change number record.� PressENTER to work through the warning.

d) In operation 40, replace work center T-C## with CENTER## and saveyour routing.

Task 4:Display your routing with different key dates to view the change history.

1. Display your routing with a key date one day before the change date (today +2 months - 1 day). Which work center is assigned to operation 40? What arethe validity dates of operation 40?

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Standard Routings→ Display or use transaction codeCA03.

b) Enter the material T-B##, plant 1000, key date one day before thechange date (today + 2 months - 1 day), and choose Enter .

c) The work center assigned to operation 40 is T-C##.

d) Double-click on the operation number and scroll to the bottom of theoperation details screen to see the validity dates. The Valid To dateshould be the change date used in the change number or two monthsfrom today.



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2. Display your routing using a key date of one day after the change date (today+ 2 months + 1 day). Which work center is assigned to operation 40? Whatare the validity dates of operation 40?


b) Enter the material T-B##, plant 1000, key date one day before thechange date (today + 2 months - 1 day), and choose Enter .

c) The work center assigned to operation 40 is CENTER##.

d) Double-click on the operation number and scroll to the bottom of theoperation details screen to see the validity dates. The Valid From dateshould be the change date used in the change number or two monthsfrom today.

Task 5:Since the new work center will replace the old one on all routings, do a massreplace with history.

1. Your new work center, CENTER## , will replace work center T-F## on allroutings two months from today. Use mass replace and change numberECN## to track history.

a) Choose Logistics→ Production→ Master Data→ Routings→ Extras→ Mass Changes→ Replace Work Center or use transaction codeCA85.

b) Enter the work center T-F##, plant 1000, new work centerCENTER##, plant 1000, change number ECN##, and choose Execute.

c) On the list, select the operations for which you want to replace thework center and choose Replace work center .

d) Check the routings you just changed to see the change and the validitydate.


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Lesson Summary

You should now be able to:� Demonstrate how to make changes with history� Demonstrate how to use where-used lists and mass changes


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PLM114 Lesson: Configuring the Routing

Lesson: Configuring the Routing

Lesson OverviewIn this lesson you will learn about the customizing settings that controll the routingat the header level and also the item level.


� Define system settings for routings

Business ExampleIn the project team, you are responsible for routing administration. You needto be aware of what options your company can take advantage of to adapt theirexisting routings to SAP ERP.

Configuring Routings: Control DataIn this step, you define number ranges for groups of routings, reference operationsets, rate routings, and reference rate routings. To create a these objects, SAP R/3requires a unique group number. You can create any of these objects with orwithout a group. If you do not enter a group number, the system assigns one tothe task list. The internal group number is within the number range you definein this step. You can also define number ranges for external assignment of groupnumbers.

Figure 131: Routing Configuration: Control Data


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In the next step, you assign number ranges you defined in the previous step to therespective task list types. Both internal and external number ranges are assignedhere. Here you can also activate the following options for each task list type:

� Write change documents� Last maintained value for the material (and plant of the material), task list

group, and sales document will default in task list maintenance

Last maintained refers to the last entry of a specific user, and not the lastentry in the system. If you would like to access fixed-user values insteadof the last maintained value, do not activate this option. Also select SETparameters and GET parameters in the field attributes of the respective field,such as the Material field. Entering a fixed value in the user parametersalone is not sufficient.

� Authorization check for deletion active.

You use this indicator to specify that a user requires deletion authority for therelevant task list to delete a task list, change the deletion flag for a task list,delete a sequence of a task list, or delete an operation or phase of a task list.If you do not set this indicator, the user only needs change authority to carryout these activities for the relevant task list type.

� Check material type against components

In this step, you maintain column headings for standard values on the operationoverview. If all work centers where operations are processed use the samedescriptions in the standard value key, the system dynamically determines acommon description for the standard value column heading. If no common headercan be determined for a column of standard values, the system sets the descriptionfrom the Customizing table according to task list type. The same procedureapplies when a sequence or a task list is created for the operation overview.

In this step you specify the line lengths of the various texts in routing long texts.The length of the short text on the corresponding overview and detail screens isalways limited to 40 characters. If the long text has more than 40 characters, theshort text will display only the first 40 characters. This table setting affects thelong texts of the following objects: header, sequence, operation, suboperation,and PRT assignment.

Configuring Routings: General DataDefine material type assignment: In this activity, you can define for eachmaterial type which task list types can be used to create routings.


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Figure 132: Routing Configuration: General Data

Define routing status: The status defines:

� Whether a reference operation set can be used in routings (Released indicator)� Whether the routing is released for costing� Whether a consistency check is run before saving (for details of the scope of

the consistency check, see the online help)

Define task list usage: You can use task list usages to create different task listsfor a material and plant, and use routing selection to control selection. The onlyparameter that can be assigned to the usage here is the dynamic modificationcriterion, which is relevant to quality management only.

The task list usage is used for:

� Automatic selection ID (as priority list regarding routing category, usage,and status) or

� User selection (ABAP routine)

Configure planner group: Check table - selection criterion

Overview variants: Overview variants can be defined for object overviews,where-used lists, and scheduling. These are not relevant to the engineeringworkbench environment.


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Profiles with Default ValuesIn this step, you define task list profiles. A profile is a collection of default valuesfor task list headers and operations. You can minimize the maintenance of tasklist data as follows:

� Data from the material master is proposed.

� Data from the work center can be referenced or copied� Data from the profile is proposed.

Figure 133: Default Values Profiles

You can enter a profile in routing maintenance. The values from this profile areproposed when you create a new routing or routing object, such as a header or anoperation. This data can either be saved or overwritten.

Use the following procedure:

1. Determine the default values that can reduce the amount of maintenancework in your company.

2. If necessary, define several profiles.3. Maintain the default values for routing maintenance.4. Maintain the default values for quality assurance.


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In this step, you can select fields for the following screens:

� Task list header screens� Sequence screens� Operation screens� PRT overview� PRT details

All of the screens where field selection is possible are combined into individualscreen groups. For each screen group, you define the modifiable and influencingfields. For modifiable fields, you use an indicator to determine how the individualfields are displayed on the screen:

� Field is ready for input (standard setting)� Field requires an entry (required entry)� Field is display only� Field is hidden� Field is highlighted

If you determine for the list and detail screens for confirmation within the networkthat work center is a required entry, you must maintain the work center in allconfirmations. For the influencing fields, you determine how the modifiable fieldis displayed on the screen, depending on a value (for example, work center is arequired entry for a certain order type).

The field selection settings you define can be transported and will remainunchanged when you upgrade to a new release. If a modifiable field becomesa required entry because of a change to an influencing field, the system doesnot check whether this field is filled with objects that already exist. You cannotmodify required fields that are already hard-coded for the application.

User-Defined Fields in OperationsUser-defined field keys are used to add data entry fields for user data to theoperation detail screen.

These field keys can offer the following fields:

Quantity Field type2 Text (20 characters)2 Text (10 characters)2 Date


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2 Quantity and unit of measure (can alsobe used by assignment to a parameterof origin 4 in formulas)

2 Value and/or currency2 Checkboxes

Figure 134: User-Defined Fields

In Customizing, the user first creates a field key name, then enters the field namefor each additional field.

The quantity fields can be used as formula parameters in formulas for calculatingexecution time and capacity requirements. These fields can also be used in productcosting.


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Lesson Summary

You should now be able to:� Define system settings for routings


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Unit Summary PLM114

Unit SummaryYou should now be able to:� Describe the different types of task lists� Describe the integration points of the task list� Assign manufactured items to routings� Allocate material components to operations� Maintain cutting measures of variable-size items� Describe the functions of suboperations� Retrieve additional fields in operations� Demonstrate how to make changes with history� Demonstrate how to use where-used lists and mass changes� Define system settings for routings


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Test Your Knowledge

1. Which of the following is not a way to create routing material assignments inSAP ERP?Choose the correct answer(s).□ A Create a material specific routing□ B Copy a materials master record and the BOM and routing are

automatically copied also□ C In the routing header create a material assignment□ D Create a production version

2. Which of the following is not a pre-requisite for component allocation?Choose the correct answer(s).□ A Operations in the routing must exist□ B Production version must exist□ C BOM for the material to be produced must exist□ D Backflush indicator must be set

3. Any materials component that is not assigned to an operation in the routingwill default to the first operation.Determine whether this statement is true or false.□ True□ False

4. Each item on the BOM can be assigned to one and only one operation onthe routing.Determine whether this statement is true or false.□ True□ False

5. Component allocation to an operation is the only additional informationwhich can be maintained with regard to components.Determine whether this statement is true or false.□ True□ False

6. Suboperations can be used for more detailed capacity planning and costing.Determine whether this statement is true or false.□ True□ False


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7. When using suboperations costing is automatically done at the operationlevel regardless of the control keys.Determine whether this statement is true or false.□ True□ False

8. You can use user-defined fields to assign data fields to an operation orsuboperation for information purposes only.Determine whether this statement is true or false.□ True□ False

9. Which of the following are ways to make changes to routings in SAP ERP?Choose the correct answer(s).□ A Without record of changes□ B With change documents□ C With history using ECM□ D All of the above

10. A where-used list can show you which task lists will be affected by a changein work center.Determine whether this statement is true or false.□ True□ False

11. It is not possible to make mass changes to routings using an ECM number.Determine whether this statement is true or false.□ True□ False


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Answers

1. Which of the following is not a way to create routing material assignments inSAP ERP?

Answer: B

There are 3 ways to create material assignments in the routing; create amaterial specific routing, create a material assignment in the header of therouting, create a production version. Material master records that are copieddo not copy the BOM and routing also.

2. Which of the following is not a pre-requisite for component allocation?

Answer: B, D

Before you can allocate components to specific operations on the routingthe operations must exist in the routing and the BOM must exist for thematerial to be produced.

3. Any materials component that is not assigned to an operation in the routingwill default to the first operation.

Answer: True

Material components in a BOM that are not assigned to an operation inthe routing are automatically assigned (default) to the first operation whenyou create a production order.

4. Each item on the BOM can be assigned to one and only one operation onthe routing.

Answer: True

Each item on the BOM can be assigned to only one operation. Items whichhave quantities of more than one and need to be assigned to more than oneoperation will need to be adjusted in the BOM to allow this type of allocation.

5. Component allocation to an operation is the only additional informationwhich can be maintained with regard to components.

Answer: False

According to the item category of the assigned components you can makefurther decisions about their processing, like backflushing of stock items orcutting size of variable-size items.


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6. Suboperations can be used for more detailed capacity planning and costing.

Answer: True

Suboperations are subordinate to an operation and used for more detailedplanning of the process step that is described in the operation. They aretypically used to carry out more detailed planning for capacity or costing.

7. When using suboperations costing is automatically done at the operationlevel regardless of the control keys.

Answer: False

When using suboperations, it is important that you ensure costs and capacityrequirements are not calculated twice by using the appropriate control keys.

8. You can use user-defined fields to assign data fields to an operation orsuboperation for information purposes only.

Answer: False

You can use user-defined fields to assign data fields to an operation orsuboperation. You can enter business information or values for formulasparameters that are not included in the standard system. The values forformula parameters could be used for calculating capacity requirements,scheduling, or costing.

9. Which of the following are ways to make changes to routings in SAP ERP?

Answer: D

Changes to routing can be made without history, with changes documents,or with history using ECM.

10. A where-used list can show you which task lists will be affected by a changein work center.

Answer: True

A where-used list can show you which task lists contain a specific workcenter and will be affected by a changed in that work center.

11. It is not possible to make mass changes to routings using an ECM number.

Answer: False

You can make changes to routings using mass change and by using anengineering change number.


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Unit 7Advanced Bill of Material Functions

Unit OverviewThis unit introduces several advanced concepts surrounding the bill of materialin SAP ERP. Not all of the following functions will be required to use during themodeling of your company's manufacturing process. These functions will includethe user of multiple bills of materials, co-products/by-products, substitute partsand other miscellaneous functions.


� Explain the concept of a phantom BOM and when it should be used� Create a phantom BOM in SAP R/3� Maintain phantom bills of material� Demonstrate model co-products and by-products� Demonstrate and explain the discontinuation process.� Model item substitutions in the bill of material� Discuss the advantages of using multiple and variant BOMs� Create a multiple BOM� Create a variant BOM� Define variant configuration� Update BOMs using mass changes� Navigate the product structure browser

Unit ContentsLesson: Phantom Assemblies.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341Lesson: Co-Products and By-Products .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345

Exercise 17: Co-Products in Production Orders ... . . . . . . . . . . . . . . . . . . . .349Lesson: Discontinuation and Substitute Parts in the Bill of Material . . . . .353

Exercise 18: Substitute Items in Production Orders .. . . . . . . . . . . . . . . . . .359Lesson: Multiple and Variant BOMS... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369

Exercise 19: Multiple/Alternative Bills of Material . . . . . . . . . . . . . . . . . . . . . .377Exercise 20: Variant BOMs ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387


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Unit 7: Advanced Bill of Material Functions PLM114

Lesson: Mass Changes and the Product Structure Browser.. . . . . . . . . . . . .393Exercise 21: Mass Changes and the Product Structure Browser.. . .397


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PLM114 Lesson: Phantom Assemblies

Lesson: Phantom Assemblies

Lesson OverviewDuring the design or manufacturing of a product, engineering often times creates�phantom� or �dummy� assemblies. The purpose of these assemblies is to makemaintenance of the item easier as the product evolves and changes.


� Explain the concept of a phantom BOM and when it should be used� Create a phantom BOM in SAP R/3� Maintain phantom bills of material

Business ExampleAs a production planned, you have some parts that are categorized as service parts.These items are used in production, but are also sold directly to customers as theitems' wear and tear requires them to be replaced. You would like the item used inproduction to be classified as a phantom bill of material.

Phantom AssembliesA phantom assembly is a logical grouping of materials. A phantom assembly isusually created within engineering to describe a number of components easily andmanage them as a whole. The components in a phantom assembly are placedimmediately into the superior assembly. As opposed to this, components in anassembly are first assembled to produce the header material. After this, the headermaterial is placed into the superior assembly.

For example, the phantom assembly �set of wheels� contains the components�front wheel� and �rear wheel.� The front and rear wheels are placed immediatelyinto the �bicycle� assembly. The �light� assembly contains the materials �bulb�and �reflector.� The light components are first assembled and then the light isattached to the bicycle.


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Figure 135: Phantom Assemblies

Phantom assemblies are used in SAP R/3 to enable the simple structuringof BOMs; the items typically do not physically exist. You can see phantomassemblies as parentheses around a group of components that are often usedin conjunction with each other. This significantly reduces the amount ofadministration needed for the master data. For changes to materials (for example,discontinued material) you only have to carry out the changes on one BOM. Thechanges have an effect on all BOMs used by the phantom assemblies.

Phantom assemblies also facilitate component assignment, since the componentsof a phantom assembly are assigned to the same operation. The same is truefor the phantom assembly itself if you have not made an assignment for thecomponents. During the BOM explosion in an SAP R/3 production order, theBOMs for phantom assemblies are also exploded. The components of the phantomassemblies become normal reservations, while the phantom assembly itself istransferred to the order as an unplanned effective reservation. The components ofa phantom assembly are connected in a hierarchy with the superordinate assembly.


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PLM114 Lesson: Phantom Assemblies

Figure 136: Setting Phantoms in SAP R/3

The settings for phantoms can occur in three different places in SAP R/3. Thehighest level to determine a part as a phantom assembly is at the material master.In the MRP 2 view, users can set an item to be a phantom assembly by setting thespecial procurement key. This means that this part at the plant level will not bemanufactured and inventoried in that form.

In addition, there are two settings that can be set in the bill of material for acomponent. In the details of the component, under the MRP section, users canuse the explosion type or special procurement. The explosion type can switch thephantom assembly off for this BOM, and it will create a planned order for the item.This overrides the material master setting. Setting the special procurement key inthe BOM to phantom assembly means that when this item is used in a the relevantBOM, it will be treated as a phantom. The settings in the BOM have priority overthe material master since they are specific to a usage or manufacturing process.


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Lesson Summary

You should now be able to:� Explain the concept of a phantom BOM and when it should be used� Create a phantom BOM in SAP R/3� Maintain phantom bills of material


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PLM114 Lesson: Co-Products and By-Products

Lesson: Co-Products and By-Products

Lesson OverviewTo model the manufacturing of multiple co-products, companies must consider thelist of all BOM components that are necessary to effectively manage the yieldsand competing resources.


� Demonstrate model co-products and by-products

Business ExampleDuring the machining of the casing for your pump, brass shavings are produced.These brass shavings are then sold back to the refiner who sold your companythe brass ingot that was used in forging the casing. As a production planneryour costing accounting group has asked you to model the brass shavings as aco-product in order to get the proper credit to manufacturing for the sale of thebrass shavings. In addition to the brass, oil is used to cool the cutting blades duringthe machining process. The oil is collected and inventoried for proper disposal.This process is regulated by the government and has not value. Model the oilused for each casing as a by-product.

Co-Products in ManufacturingA co-product is a material that is manufactured simultaneously with the mainproduct. In certain cases, the main material cannot be manufactured in isolation,without also producing the co-product, for a given production process.


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Figure 137: Manufacture of Co-Products

Use in ECC PP-PI Module: The process industry is full of numerous examples,where due to the nature of the chemical and biological reactions, there is aconcurrent yield for multiple products. Typically there is one main product beingmanufactured. The rest of the products could be categorized as co-products,by-products, waste products. Co-products and by-products have a non-zeroinventory valuation, as opposed to waste products having a zero unit cost.Furthermore, since the co-products label is given to products that have a highercost visibility, then any other generic by-product in your company, the co-productsare also earmarked for cost settlement at the end of the process order life cycle.

Figure 138: Co-Products in the BOM


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Main Leading Material and Co-Product - Structure: Co-products, by-products,and waste products are set up as a negative quantity components in the BOMof the Master Recipe. Since co-products have further cost settlements, a seriesof indicators have to be setup in the product masters and the BOM. All of theproduct masters, and the negative quantity components must have the co-productindicator fields check marked. Also the cost apportionment ratios for all of thecost components that are involved with the co-products, have to be defined intheir product masters.

To better understand Co-products we first must understand several related terms.All of these terms are used frequently in the Food, Chemicals, Electronics, andother process, repetitive and flow manufacturing industries.

Co-productIn ECC a co-product is a material that is manufactured simultaneously withthe main product. The main material cannot be manufactured in isolation,without also producing the co-product, for a given production process.Co-products have a non-zero inventory valuation. Co-products are alsoearmarked for cost settlement at the end of the process order life cycle, andappear in the header settlement rule.

By-productIn ECC a by-product is a material that is manufactured simultaneously withthe main product. The main material cannot be manufactured in isolation,without also producing the by-product, for a given production process.By-products have a non-zero inventory valuation. By-products are notearmarked for cost settlement at the end of the process order life cycle, anddo not appear in the header settlement rule.

Waste productIn ECC a waste product is a material that is manufactured simultaneouslywith the main product. The main material cannot be manufactured inisolation, without also producing the waste product, for a given productionprocess. Waste products have a zero inventory valuation. Waste products arenot earmarked for cost settlement at the end of the process order life cycle,and just like by-products, do not appear in the header settlement rule.


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Exercise 17: Co-Products in ProductionOrders

Exercise ObjectivesAfter completing this exercise, you will be able to:� Explain how to set up co-products in SAP ERP

Business ExampleThe stamping and assembly operations of the pump yields two additional gasketswhich are not needed for the pump, but they have value. You need to put theminto inventory.

Task 1: Define co-products on the BOM1. Define material T-G##, plant 1000 as a co-product on the BOM of pump

T-F1##.

Task 2: Optional: Test the co-product setting

1. Create a production order for T-F1##. View the co-product results in thestock requirements list.


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Solution 17: Co-Products in ProductionOrdersTask 1: Define co-products on the BOM1. Define material T-G##, plant 1000 as a co-product on the BOM of pump

T-F1##.

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Change.

b) Enter the following data from the table below.

Field EntryMaterial T-F1##

Plant 1000

BOM Usage 1

c) Choose Enter .

d) Enter the following in the first available component item on theGeneral Item Overview screen.

Field EntryComponent T-G##

Quantity 2-

e) Choose Enter .

f) Go to the item details by double-clicking the item number orhighlighting the line and selecting the item icon (or pressing F7).

g) On the Basic Data tab, select the Co-product indicator.

h) Save the BOM.



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Task 2: Optional: Test the co-product setting

1. Create a production order for T-F1##. View the co-product results in thestock requirements list.

a) Choose Logistics→ Production→ Production Control→ Order→Create→ With Material (CO01).

b) Enter the following data and press ENTER.


Plant 1000

Order Type PP01

c) Enter only the following two items and choose Save.

Field EntryTotal Qty 10

Finish Current date + 1 month

Hint: If a message regarding costs is displayed; choose Yes tocontinue and save the order.

d) Choose Logistics → Production → MRP → Evaluations →Stock/Requirements List.

e) Enter the data from the table below.

Field EntryMaterial T-G##

MRP Area <blank>

Plant 1000

f) Choose Enter .

g) A production order has been created for the co-product to be receivedinto inventory. The quantity has been calculated based on the BOMquantity.


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Lesson Summary

You should now be able to:� Demonstrate model co-products and by-products


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PLM114 Lesson: Discontinuation and Substitute Parts in the Bill of Material

Lesson: Discontinuation and Substitute Parts in the Billof Material

Lesson OverviewBOMs are seldom static. Component materials are replaced by other items.Certain components may also be substituted if the need arises. In this lesson, wewill introduce discontinuation and alternative items as methods to manage suchsituations.


� Demonstrate and explain the discontinuation process.� Model item substitutions in the bill of material

Business ExampleIn the manufacturing of several of your products, you use an extensive amount ofwiring. The wiring is inventoried as several different part numbers, based on thegrade of wire. In the event of an inventory shortage, engineering has authorizedthe use of higher grade wire in place of the standard item. As a productionplanner, you need to model this to assure that production orders can be completedwhen released to the shop floor. You want to model this substitution processin your bill of material.

Item Substitution in the Bill of MaterialThe engineering and design department may specify that a material is to bereplaced by another at a particular point in time. These changes may be necessaryfor the following reasons:

� New safety regulations may apply after a certain point in time. As a result,a certain component may have to be replaced, as it no longer meets thesafety requirements.

� A cost-intensive part may be replaced by a less expensive one.

Discontinuation control works in the same way for long-term master productionand requirements planning.


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Figure 139: Discontinuation Control (Simple Discontinuation)

Simple Discontinuation: A component that is to be discontinued is replaced bya follow-up material as of a certain date, as soon as the stock available for MRPof the discontinued component is zero. This means that when the stock availablefor MRP of the discontinued material is zero, the dependent requirements arediverted from the discontinued material to the follow-up material. If the follow-upmaterial is not available for MRP, the follow-up material is then acquired (in placeof the discontinued material). The safety stock of the discontinued material isnot affected by requirements planning.

If the stock available for MRP for the discontinued material becomes greaterthan zero again, due to a later order for instance, the material is used again. Anexception message for goods deliveries subsequent to the discontinued date isalso produced.

Prerequisites: In the material master record of the discontinued component,the discontinued indicator is set to 1, a follow-up material is entered, and adiscontinued date is set. For information purposes, the follow-up material can bemaintained in the BOM as a follow-up material.


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Figure 140: Discontinuation Control (Parallel Discontinuation)

Parallel discontinuation: One group of materials is replaced by another groupof materials, for instance, where one (main) component is discontinued andits available stock is zero, and another (dependent) component must also bediscontinued. For example, a certain nut may be discontinued, meaning thecorresponding screw is also discontinued.

Prerequisites:

� In the material master record of the main discontinued component, thediscontinued indicator is set to 1 and the follow-up indicator 3 appears in thematerial master record of the dependent discontinued component.

� In the extras for the BOM item, define a discontinuation group underfollow-up/discontinued dates; this freely definable character string containsa summary of the associated, discontinued items of a BOM. The maincomponent to be discontinued and its dependent component are identifiedusing the same discontinuation group.

� You can also define the follow-up component(s) using the follow-up itemindicator. The succeeding group contains a summary of the associatedfollow-up items in a BOM; it determines by which follow-up items thediscontinued items are to be replaced. The character string of the succeedinggroup must correspond with the character string of the discontinued group.


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Figure 141: Alternative Items

Alternative Items: Grouping

This serves to summarize alternative items within an item list. All assemblymaterials can be entered into the alternative item group. As soon as you create analternative item group, you will receive an additional dialog window containingthe ranking order, strategy, and probability of usage. You can maintain alternativeitems for the following situations:

� Alternative items with specified usage probability

These alternative items incorporate a certain usage probability. Create ausage probability for each alternative item in a group, so that in requirementsplanning a dependent requirement is created and this is changed to areservation in the production order.

� Alternative items as information

You can also create an alternative item for information purposes, for instance,that is only referenced in missing part situations. As neither a dependentrequirement nor a reservation will occur for this item, you do not producea usage probability.


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Figure 142: Alternative Item Data Detail Screen

� Backflush according to usage probability

For all items that are to be reserved, maintain the:

� Strategy (value 1 or no entry)� Ranking order (only affects the sorting of materials)� Usage probability

� Backflush at 100% availability

For all items that are to be reserved, maintain the

� Ranking order; if no ranking order is entered, the system checks theitems in the order in which they are transferred for availability check(value 1 or no entry)

� Strategy (value 2)� Usage probability

� Backflush at 100% availability (strategy 2)

With this strategy, the availability check is executed in the specified rankingorder according to ATP logic.

Gross requirements: 100 pieces


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Material UsageProbability

Rank-ing

PlannedRequire-mentAmount

ATPQuan-tity:

Backflushquantity

A 20 1 20 30 0B 30 2 30 150 100C 50 3 50 180 0

� The first material in the ranking order that meets the requirement date 100%is reserved in the required quantity (material B).

� Once a partial backflush has occurred for a production order, no furthercheck takes place for further partial flushes with this production order. Anyfuture partial backflushes take place from the alternative item from whichthe first backflush occurred.

� If, with strategy 2, none of the alternative items meet the requirements 100%,the availability check confirms each available quantity. A reservation isthen made for the available quantity.


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Exercise 18: Substitute Items inProduction Orders

Exercise ObjectivesAfter completing this exercise, you will be able to:� Enter alternative items on a BOM

Business ExampleCertain materials must be used as a substitute in case the standard material isnot available.

Task 1:Optional: Create alternative items in the BOM T-F1##.

1. Use the requirements/stock list to display the current stock available for thefollowing materials:

T-B1##T-B2##T-B3##T-B4##T-T3##T-Z##

Change the stock for the above materials in plant 1000 at storage location0001 to the following status:

T-B1## 100 pieces (exact)T-B2## 200 pieces (minimum)T-B3## 200 pieces (minimum)T-B4## 200 pieces (minimum)T-T3## 1800 pieces (minimum)T-Z## 200 pieces (minimum)



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2. Change the BOM of material T-F1## by creating the new component T-Z##as an alternative item to T-B1##. For item T-B1##, enter Alt.item group 01,Priority 1, Strategy 2, and Usage probability 100. For item T-Z##, enterAlt.item group 01, Priority 2, Strategy 2, and Usage probability 1.

Task 2:Optional: Using a production order, test the effects of the alternative item(s).

1. Test the effects of the alternative item group on production planning andmaterial backflush.

Create a production order for the material T-F1## in plant 1000 for LESSTHAN 100 pieces. Use the order category PP01. Select one month fromtoday's date as the order finish date. After confirming the data entries withENTER, go to the component overview to find the answers to the followingquestions:

How high is the quantity requirement of T-B1##? ____________How high is the confirmed quantity of T-B1##? ____________How high is the quantity requirement of T-Z##? ____________How high is the confirmed quantity of T-Z##? ____________

Caution: Do not save the order yet.

2. Carry out an availability check for all components.


Exit and do not save the order.

3. Repeat the last two steps to test the effect of the alternative item groups inthe case of insufficient stock.

Create a production order for the material T-F1## in plant 1000 forMORETHAN 100 pieces. Use the order category PP01. Select one month fromtoday's date as the order finish date. After confirming your data entrieswith ENTER, go to the Component overview to find the answers to thefollowing questions:



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Caution: Do not save the order at this point.



Do not save the order.


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Solution 18: Substitute Items inProduction OrdersTask 1:Optional: Create alternative items in the BOM T-F1##.

1. Use the requirements/stock list to display the current stock available for thefollowing materials:

T-B1##T-B2##T-B3##T-B4##T-T3##T-Z##

Change the stock for the above materials in plant 1000 at storage location0001 to the following status:

T-B1## 100 pieces (exact)T-B2## 200 pieces (minimum)T-B3## 200 pieces (minimum)



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T-B4## 200 pieces (minimum)T-T3## 1800 pieces (minimum)T-Z## 200 pieces (minimum)

a) For analysis of current requirements/stock situation, choose Logistics→ Production→ MRP→ Evaluations→ Stock/Requirements Listor use transaction MD04.

Stock is displayed in the top line.

b) For any necessary deliveries of goods, choose Logistics→ MaterialsManagement→ Inventory Management→ Goods Movement→ GoodsReceipt→ Other or use transaction MB1C.

c) Enter transaction type 561, plant 1000, storage location 0001,today's date as document and Posting Date, and leave the otherfields empty or enter default differences.

d) For any necessary issues of goods choose Logistics→ MaterialsManagement→ Inventory Management→ Goods Movement→ GoodsIssue or use transaction MB1A.

e) Use the movement category 201 and the cost center 1000.



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2. Change the BOM of material T-F1## by creating the new component T-Z##as an alternative item to T-B1##. For item T-B1##, enter Alt.item group 01,Priority 1, Strategy 2, and Usage probability 100. For item T-Z##, enterAlt.item group 01, Priority 2, Strategy 2, and Usage probability 1.

a) Add component T-Z##.

Choose Logistics -> Production -> Master Data -> Bills of Material-> Bill of Material -> Material BOM -> Change or use transactioncode CS02.

b) In the first available row, enter item T-Z## with the quantity 1piece.

c) Set T-Z## as an alternative to T-B1##.

d) Select both components on the General Item Overview screen andselect Details .

e) In the details for component T-B1##, enter AltItemGroup 01 andpress ENTER.

f) Enter the following in the Alternative Item Data dialog box.

Field EntryPriority 1

Strategy 2

Usage Prob. 100

g) Press ENTER and choose Next Item to proceed to the details forcomponent T-Z##.

h) In the details for component T-Z##, enter AltItemGroup 01 and pressENTER.

i) Enter the following in the Alternative Item Data dialog box.

Field EntryPriority 2

Strategy 2

Usage Prob. 1

j) Press ENTER.

k) Save the BOM.



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Task 2:Optional: Using a production order, test the effects of the alternative item(s).

1. Test the effects of the alternative item group on production planning andmaterial backflush.

Create a production order for the material T-F1## in plant 1000 for LESSTHAN 100 pieces. Use the order category PP01. Select one month fromtoday's date as the order finish date. After confirming the data entries withENTER, go to the component overview to find the answers to the followingquestions:


Caution: Do not save the order yet.

a) To create a production order, choose Logistics→ Production→Production Control→ Order→ Create→ With Material or usetransaction code CO01.

b) Enter the material number, plant, and order type on the initial screenand press ENTER.

c) On the next screen, enter the total quantity and the order finish dateof today + 1 month and press ENTER.

d) Go to the Components overview using the button.

Quantity requirement of T-B1## variesConfirmed quantity of T-B1## 0Quantity requirement of T-Z## 1Confirmed quantity of T-Z## 0





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Exit and do not save the order.

a) Choose Availability Check .

Quantity requirement of T-B1## varies (ALL)Confirmed quantity of T-B1## varies (ALL)Quantity requirement of T-Z## 0Confirmed quantity of T-Z## 0

3. Repeat the last two steps to test the effect of the alternative item groups inthe case of insufficient stock.

Create a production order for the material T-F1## in plant 1000 forMORETHAN 100 pieces. Use the order category PP01. Select one month fromtoday's date as the order finish date. After confirming your data entrieswith ENTER, go to the Component overview to find the answers to thefollowing questions:



a)

Quantity requirement of T-B1## varies (ALL)Confirmed quantity of T-B1## 0Quantity requirement of T-Z## 1Confirmed quantity of T-Z## 0




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Do not save the order.

a)

Quantity requirement of T-B1## 0

Confirmed quantity of T-B1## 0Quantity requirement of T-Z## varies (ALL)Confirmed quantity of T-Z## varies (ALL)

Exit without saving the order.


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Lesson Summary

You should now be able to:� Demonstrate and explain the discontinuation process.� Model item substitutions in the bill of material


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PLM114 Lesson: Multiple and Variant BOMS

Lesson: Multiple and Variant BOMS

Lesson OverviewVariant and multiple bills of material are a method to manage BOMs. We willdiscuss the circumstances and advantages of each.


� Discuss the advantages of using multiple and variant BOMs� Create a multiple BOM� Create a variant BOM� Define variant configuration

Business ExampleTwo situations many occur that may increase the number of BOMs that need tobe managed. First, a single material may have more then one list of components.We will use multiple BOMs to manage these. Second, many materials may usesimilar components. We will use variant BOMs for these.

Multiple BOMsOne product may be made of different combinations of components, depending onthe quantity (lot size) to be manufactured or the date. This type of product is oftenrepresented by alternative BOMs (alternatives). These alternative BOMs differonly slightly from one another, usually in terms of the component quantity.


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Figure 143: Multiple BOM: One Product

The field BOM group can also be used as an external BOM number.

All alternatives for a multiple BOM are saved under one internal BOM number.

You can assign one name to all the alternatives in a multiple BOM by entering aBOM group in the BOM header.

Figure 144: Multiple BOM

The plant and usage are part of the unique key that identifies a BOM.

Each alternative has a BOM header.


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The alternative is selected according to the selection method indicator in thematerial master record:

� Lot size� Date� Production version

Variant BOMsIf several similar products are manufactured whose parts only differ in minorways, you can represent these various products using a variant BOM. Variantscan also differ in component quantity alone.

Figure 145: Variant BOM: Several Products

Only a simple (basic) material BOM can be extended to become a variant BOM.

You cannot convert a multiple BOM into a variant BOM.


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Figure 146: Variant BOM

You can create a variant only if:

� A BOM does not already exist for the material.� The base unit of measure of all variant materials is the same. This is because

the base unit of measure of the bill of material must be the same as the baseunit of measure of the material master record.

Figure 147: Variant BOM (2)

Several products created as variants of a variant BOM are saved under one internalBOM number. You can give a name to all of the variants of a variant BOM byentering a BOM group in the BOM header. Each variant has its own materialnumber.

The field BOM group can also be used as an external BOM number.

The plant and the BOM usage are part of the unique key of a bill of material.


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Each variant has a BOM header.

You can create a variant only if:

� A BOM does not already exist for the material.� The base unit of measure of all variant materials is the same. This is because

the base unit of measure of the bill of material must be the same as the baseunit of measure of the material master record.

Figure 148: Different Types of BOMs

Variant ConfigurationWhen dealing with multivariant products, the combinations of individual productfeatures give rise to a vast range of variants.

Complex products mean complex configuration tasks in both sales and production.A company that sells or produces products with variants must perform theseconfiguration tasks quickly and accurately.


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Figure 149: Variant Configuration

However, this is not easy, as product development cycles and life cycles ofproducts are becoming shorter than ever before.

Standard product is a general term used to define a product that is to bemanufactured in multiple variants. It covers all the possible features of the variantproduct, and therefore does not refer to one specific article.

The features of configurable products are defined the SAP system ascharacteristics.

Figure 150: Configuration of a Pump


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There are often inter-dependencies between the individual forms of a product. Itis frequently the case that not all combinations that are theoretically possible areallowed. There are two reasons for this:

� Some combinations are not possible for technical reasons.� Other combinations may not be allowed for marketing and sales reasons. For

example, if you want to order a motorcycle, you may only be able to havecertain colors of paint and seats if you are ordering an expensive model.

Instead of creating a separate BOM for each product variant, you can group thecomponents together into a super BOM. This super BOM consists of parts thatappear in all variants of the product, and others that can be chosen and includedin the product depending on the variant. You use object dependencies to definewhich components are selected under which conditions.

In the sales order, an individual product structure is created dynamically.


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Exercise 19: Multiple/Alternative Bills ofMaterial

Exercise ObjectivesAfter completing this exercise, you will be able to:� Maintain an alternative/multiple BOM

Business ExampleYou need to group together bills of material for �blue paint� in a multiple BOM.

Task: Maintaining Alternative/Multiple BOMsThe BOM for �blue paint� (material number T-F77## (## = group number) hasdifferent components or component quantities for different lot sizes.

1. Create a BOM for the paint in plant 1000 with the following data:

Material T-F77##, BOM group Color-##, and BOM text �multiple BOMgroup ##�.

Item Item cat. Component Quantity Un10 L T-B71 0,5 kg20 L T-B74 1 kg30 L T-B75 1 kg

2. Create an alternative by copying alternative 1. In this alternative, replaceitem 10, component T-B71, with the item below and change the quantityof item 20:

Item Item cat. Component Quantity Un10 L T-B72 0.3 kg

Change the quantity of component T-B74 in item 20 to 1.4 l.

3. Create another alternative by copying alternative 1. In this alternative,replace item 10, component T-B71, with the following:


4. Add the following data to the BOM headers of the alternatives:Continued on next page


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Alternative Alt text Lot size from to1 Paint Color 1 1 1002 Paint Color 2 101 2003 Paint Color 3 201 500

5. Display all alternatives of T-F77## (BOM group Paint-##).

Check your entries. Pay particular attention to the following:

BOM group ____________

Internal BOM number ____________

Technical type ____________

6. Optional: Create a production order with the material T-F77## and test theeffects of the different BOM alternatives with your lot sizes.

The production order should be for plant 1000, order type PP01, formore than 125 pieces and for 2 months from today. Since there is noworking schedule, let the system create an operation. Without changingthe production order, check which BOM alternative has been associated.Why was this used?

Alternative ____ because ______________________________

Change the order quantity to 225 pieces and update the PP master data.Why this alternative?


7. Optional: Maintain a multiple BOM for the different alternatives.

Select of alternatives according to date.

Example:

Material Plant BOMusage

Valid from BOM Alt

T-F77## 1000 1 01/01/xxxx 1T-F77## 1000 1 01/07/xxxx 2T-F77## 1000 1 01/12/xxxx 3


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Solution 19: Multiple/Alternative Bills ofMaterialTask: Maintaining Alternative/Multiple BOMsThe BOM for �blue paint� (material number T-F77## (## = group number) hasdifferent components or component quantities for different lot sizes.

1. Create a BOM for the paint in plant 1000 with the following data:

Material T-F77##, BOM group Color-##, and BOM text �multiple BOMgroup ##�.



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Item Item cat. Component Quantity Un10 L T-B71 0,5 kg20 L T-B74 1 kg30 L T-B75 1 kg

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Create: .



Plant 1000

Usage 1


c) Choose Enter .

d) On the Item overview screen, enter the following data:

Item Item cat. Component Quantity10 L T-B71 0.520 L T-B74 130 L T-B75 1

e) Give the BOM group a name:Paint-##.

f) Go to the BOM Header .

g) In the BOM Group field, enter PAINT-##.

h) Save the BOM.

2. Create an alternative by copying alternative 1. In this alternative, replaceitem 10, component T-B71, with the item below and change the quantityof item 20:




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Change the quantity of component T-B74 in item 20 to 1.4 l.

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Create:



Plant 1000

Usage 1


c) Select copy from or press F7.

d) Confirm the warning �Alternative 2 added to BOM.�

e) Enter alternative 1 in the dialog box and choose Enter.

f) Select all of the components to copy and choose Copy again.

g) Change the following two rows in the item overview:

Item no. Item cat. Component Quantity10 L T-B72 0.3 kg20 L T-B74 1.41

h) Save the BOM

3. Create another alternative by copying alternative 1. In this alternative,replace item 10, component T-B71, with the following:



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a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Create:



Plant 1000

Usage 1


c) Select copy from or choose F7.

d) Confirm the warning �Alternative 3 added to BOM.�

e) Enter Alternative 1 in the dialog box and choose Enter.

f) Select all of the components to copy and choose Copy again.

g) Change the following in the item overview:

Item no. Item cat. Component Quantity10 L T-B73 0.3 kg

h) Save the BOM

4. Add the following data to the BOM headers of the alternatives:



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Alternative Alt text Lot size from to1 Paint Color 1 1 1002 Paint Color 2 101 2003 Paint Color 3 201 500

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ Change:



Plant 1000

Usage 1


c) Select alternative 1 and select the Header icon .

d) On the Quantities/Long text tab page, (F6) add the following: Alt text.Paint Color 1 and lot size from 1 to 100.

e) Repeat steps for alternatives 2 and 3.

5. Display all alternatives of T-F77## (BOM group Paint-##).

Check your entries. Pay particular attention to the following:

BOM group ____________

Internal BOM number ____________



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Technical type ____________

a) Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ BOM Group→ Display:


Field EntryBOM group Paint-##

Plant 1000

Usage 1


c) Choose Goto→ Alternative overview. Three alternatives should nowbe displayed. Select all alternatives and choose the Header icon .

Hint: Switch between the three different alternatives using

the Next alternative icon .

d) BOM number, usage 1 and technical typeM should be the same inall alternatives.

Alternative texts and lot sizes should be different for each alternative(see defaults).

6. Optional: Create a production order with the material T-F77## and test theeffects of the different BOM alternatives with your lot sizes.

The production order should be for plant 1000, order type PP01, formore than 125 pieces and for 2 months from today. Since there is noworking schedule, let the system create an operation. Without changingthe production order, check which BOM alternative has been associated.Why was this used?


Change the order quantity to 225 pieces and update the PP master data.Why this alternative?



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a) Choose Logistics→ Production→ Production control→ Order→Create→ with material.



Production plant 1000

Order type PP01

c) Choose Enter. Enter the following data.

Total quantity 125

Order finish date 2 months from today

d) Choose Enter.

Ignore the message � no working schedule found .�

e) Choose generate process.

f) On the Master data tab page, enter BOM Alt. 2 (because ofquantity).

g) Now change quantity to 225 pieces. Choose Functions→ Read PPmaster data→ Read BOM only. Enter BOM Alt. 3 (because ofquantity).

h) Exit the order without saving.

7. Optional: Maintain a multiple BOM for the different alternatives.

Select of alternatives according to date.

Example:



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Material Plant BOMusage

Valid from BOM Alt

T-F77## 1000 1 01/01/xxxx 1T-F77## 1000 1 01/07/xxxx 2T-F77## 1000 1 01/12/xxxx 3

a) Choose Logistics→ Production→ Master Data→ Bills of Material→ Bill of Material. or Logistics→ Central functions→ Engineering→ Bill of Material→ Material→ Material BOM→ BOM group→Create or change or use transaction code CS05....

b) On the initial screen, choose Settings→ Current settings.

c) Double-click the Execute icon to view the multiple BOM.

d) Maintain data as described in exercise and Save.


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Exercise 20: Variant BOMs

Exercise ObjectivesAfter completing this exercise, you will be able to:� Maintain a variant BOM

Business ExampleThe engineering department requires BOMs to efficiently maintain simple butsimilar materials.

Task:You now want to create two additional variants of the pump T-F## in plant 1000with where-used list 1.

These are pumps T-FY## and T-FZ##.

1. Create a BOM for pump T-FY## as a variant of T-F##. Replace componentT-B## with T-B1##. Enter the following header data.

BOM text �Standard pump�Alternative Text Y variant and Z variant

BOM group VA##

2. Create a BOM for pump T-FZ## as a variant of T-F##. Replace component100-300 with T-BZ##.

3. Display all variants of T-F## (BOM group VA##).

Check your entries are correct. Check in particular:

BOM group _______________Internal BOM number _______________Technical type _______________

4. Enter BOM item 100-801 in BOM group maintenance (any quantity youchoose), which is only valid for variants T-FY## and T-FZ##. Check theresult.


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Solution 20: Variant BOMsTask:You now want to create two additional variants of the pump T-F## in plant 1000with where-used list 1.

These are pumps T-FY## and T-FZ##.

1. Create a BOM for pump T-FY## as a variant of T-F##. Replace componentT-B## with T-B1##. Enter the following header data.



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BOM text �Standard pump�Alternative Text Y variant and Z variant

BOM group VA##

a) Create an additional variant for pump T-FY##.

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

b) Enter the data below.

Material T-FY##

Plant 1000 (Default)Usage 1 (Default)Valid from Today's date (Default) do not

press <Enter>

c) Choose .

d) Enter Material T-F## in the Create variant of... dialog box.

Choose Enter .

e) Select all components to be copied and choose the Copy icon .

f) Enter header data from the table below:

BOM group VA##

BOM text Standard pump

Alt text Y variant

Confirm with Enter.

g) In the Item Overview, change the component below:

Item no. Item cat. Component Quantity10 L T-B1## 1

h) Save the BOM.



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2. Create a BOM for pump T-FZ## as a variant of T-F##. Replace component100-300 with T-BZ##.

a) Create additional variant for pump T-FZ##.

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

b) Enter the following data.

Material T-FZ##

Plant 1000 (Default)Where-used list 1 (Default)Valid from Today's date (Default) do not

press <Enter>

c) Choose .

Enter Material T-F## in the Create variant of... dialog box.

d) Choose Enter .

e) Select all components to be copied and choose the Copy icon .

f) In the Item Overview, change the component below:

Item no. Item cat. Component Quantity30 L T-BZ## 1

g) Save the BOM.

3. Display all variants of T-F## (BOM group VA##).

Check your entries are correct. Check in particular:



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BOM group _______________Internal BOM number _______________Technical type _______________

a) Display your BOM group.

Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ BOM Group→ Display.

b) Enter the following data.

BOM group VA##

Plant 1000

Valid From Today's date

Choose Enter.

c) Select Variants .

d) Select all variants and choose the Header button .

BOM number, usage 1, and technical type V exist only once.

Hint: In the header, choose : Item. You can then move betweenthe individual variants using the Previous Variants and NextVariants buttons.

In the summarized BOM, choose Variant items to view selecteditems.

4. Enter BOM item 100-801 in BOM group maintenance (any quantity youchoose), which is only valid for variants T-FY## and T-FZ##. Check theresult.

a) Change your BOM group.

Choose Logistics→ Production→Master Data→ Bills of Material→Bill of Material→ Material BOM→ BOM Group→ Change.

b) Enter BOM Group VA## and press ENTER.

c) Enter component material 100-801 and a quantity in the first availablecomponent item, and set the Item indicator in alternative/variant 02 and03 for variants T-FY## and T-FZ##.

d) Save the BOM.


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Lesson Summary

You should now be able to:� Discuss the advantages of using multiple and variant BOMs� Create a multiple BOM� Create a variant BOM� Define variant configuration

Related InformationVariant configuration is taught in the following SAP courses:

� PLM130 Classification� PLM140 Variant Configuration 1 � Modeling� PLM143 Variant Configuration 2 � Integration� WNAP45 Variant Configuration 1 & 2 - Modeling and Integration� PLM146 Variant Configuration 3 � Scenarios


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PLM114 Lesson: Mass Changes and the Product Structure Browser

Lesson: Mass Changes and the Product StructureBrowser

Lesson OverviewIn this lesson, we will discuss mass changes and the product structure browser inbills of material.


� Update BOMs using mass changes� Navigate the product structure browser

Business ExampleA component material is used on many BOMs and must be replaced.

All the objects in a structure have to be displayed, processed, or created.

Mass Changes and the Product Structure BrowserYou can use the mass change function to make changes to items in several BOMsusing only one function call.

Figure 151: Mass Change in BOMs


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The following item changes are supported for material items, document items,and class items:

� Changing the component quantity� Changing the item data� Adding of items� Replacing an item

� In all selected BOMs� With assignment of a new item quantity if necessary� Using Engineering Change Management if necessary� With restrictive selection criteria such as plant and/or usage

� Deleting an item

� In all selected BOMs� Using Engineering Change Management if necessary� With restrictive selection criteria, such as plant and/or usage

Figure 152: Product Structure

The product structure enables you to display and process all functionally relatedobjects (such as material, BOM, document, and routing). The product data isdisplayed in a tree structure. You can restrict the display to only the detail datarequired for the current processing situation.

You can explode the product structure across different systems. Data can beevaluated and processed either locally or in multiple systems (Application LinkEnabling [ALE] destinations).


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You can:

� Go directly to display mode or processing mode for individual objects� Display or process similar objects� Create an additional tree structure for any object� Select several objects for object management records in Engineering Change

Management� Jump to the engineering workbench


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Exercise 21: Mass Changes and theProduct Structure Browser

Exercise ObjectivesAfter completing this exercise, you will be able to:� Analyze and navigate your product structure

Business ExampleThe design engineer wants an overview of all existing objects for his pump inorder to process them as and when required.

Task:Navigate the Product Structure Browser

1. Take a look at the product structure for material T-F##.

Display the BOM and open a document info record.

Display the BOM for the assembly.

2. Change item 0010 for BOM T-F## in plant 1000.

Double the required quantity for component 0010.

3. Go to the classification and display the characteristics for your pump.

Pump height: ____________

Pump capacity: ____________

Usage: ____________


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Solution 21: Mass Changes and theProduct Structure BrowserTask:Navigate the Product Structure Browser

1. Take a look at the product structure for material T-F##.

Display the BOM and open a document info record.

Display the BOM for the assembly.

a) Open the product structure browser

Choose Cross-Application Components→ Engineering ChangeManagement→ Environment→ Product Structure or Logistics→ Central Functions → Engineering → Engineering ChangeManagement→ Environment→ Product Structure.

b) Enter the material T-F## on the Material tab page and choose Enter

.

c) Expand the tree structures for bills of material and documents byclicking on the hierarchy node.

d) Double-click on the symbols for bill of material or document to displaythe corresponding master record. You can also click on the eyeglassesto the right to display the documents.

e) Select the individual objects then right-click to display a context menu.From the context menu, you can display or change objects or go to theengineering workbench.

f) To recognize which T-F## components are also assemblies, werecommend placing the assemblies indicator in the layout.

Select the right-hand side of the Change Layout button .

g) Select the right-hand side of the Filter button and chooseBOM item.

h) Highlight the Assembly field and move to the left using the buttonand then choose Enter.

i) To display the BOM of an assembly, expand the appropriate node andright-click.

2. Change item 0010 for BOM T-F## in plant 1000.



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Double the required quantity for component 0010.

a) Open the tree structure of BOM T-F## in plant 1000 at item level.Select the header of the BOM and right-click. Select Change.

b) Double-click on the item number 0010.

c) Change the required quantity.

d) Choose Save.

3. Go to the classification and display the characteristics for your pump.

Pump height: ____________

Pump capacity: ____________

Usage: ____________

a) Expand the hierarchy node Classification and select the Class.

b) Right-click and select Characteristic Value Assignment or choose the

Values icon .

c) Pump height: 5 m (may vary)

Pump capacity: 15 m3 (may vary)

Usage: House technology (may vary)


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Lesson Summary

You should now be able to:� Update BOMs using mass changes� Navigate the product structure browser


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PLM114 Unit Summary

Unit SummaryYou should now be able to:� Explain the concept of a phantom BOM and when it should be used� Create a phantom BOM in SAP R/3� Maintain phantom bills of material� Demonstrate model co-products and by-products� Demonstrate and explain the discontinuation process.� Model item substitutions in the bill of material� Discuss the advantages of using multiple and variant BOMs� Create a multiple BOM� Create a variant BOM� Define variant configuration� Update BOMs using mass changes� Navigate the product structure browser


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Unit Summary PLM114


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Test Your Knowledge

1. A component with a negative quantity exists on a BOM. Select each of thefollowing that it could be.Choose the correct answer(s).□ A Co-product□ B By-product□ C Waste product□ D Recursive product

2. Co-products, by-products, and waste products are materials on the BOMwhich you can choose to produce.Determine whether this statement is true or false.□ True□ False

3. One of the differences between co-products, by-products, and waste productsis their inventory valuation and settlement.Determine whether this statement is true or false.□ True□ False

4. In order to use a material on a BOM as a co-product, you must first enable itto be used as a co-product in the material master.Determine whether this statement is true or false.□ True□ False


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Answers

1. A component with a negative quantity exists on a BOM. Select each of thefollowing that it could be.

Answer: A, B, C

A component on a BOM with a negative quantity could be a co-product,by-product, or a waste product.

2. Co-products, by-products, and waste products are materials on the BOMwhich you can choose to produce.

Answer: False

Co-products, by-products, and waste products are materials on the BOM thatare created simultaneously with the main product. The main product cannotbe produced in isolation without producing these.

3. One of the differences between co-products, by-products, and waste productsis their inventory valuation and settlement.

Answer: True

Co-products have non-zero inventory valuation and are earmarked for costsettlement. By-products have a non-zero inventory valuation but are notearmarked for cost settlement. Waste products have zero inventory valuationand are not earmarked for cost settlement.

4. In order to use a material on a BOM as a co-product, you must first enable itto be used as a co-product in the material master.

Answer: True

In order to use a material as a co-product on a BOM you must set theco-product indicator on the MRP 2 view of its material master record. Inaddition, you should also define the apportionment structure under the jointproduction button for cost settlement.


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Unit 8Advanced Routing Functions

Unit OverviewThis unit introduces several advanced concepts surrounding the use of routingsin SAP ERP. Not all of the following functions will be required to use during themodeling of your company's manufacturing process. These functions will includethe user of parallel and alternative operations, detailed scheduling segments, scrapand other miscellaneous functions.


� Use parallel sequences in modeling complex manufacturing processes� Use alternative sequences in modeling flexible manufacturing processes� Model alternative manufacturing processes using alternative routings� Use production versions to model a very specific production process� Utilize reference operation sets to minimize routing maintenance� Create a reference operation set� Use a reference operation set in a routing� Use a reference operation set as a template to create a routing� Describe in detail the concept of lead time scheduling and updating in-house

production time in the material master� Identify the data used in lead time scheduling� Explain how the SAP ERP system uses the data to determine the lead time

schedule� Update the material master record of a material from the routing� Demonstrate the use of interoperation times in the routing for job shop

related environments� Demonstrate the use of Overlapping for a continuous manufacturing process� Demonstrate the use of splitting for multi-capacity work centers.� Describe the use of trigger points to streamline and automate several

administrative processes


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Unit 8: Advanced Routing Functions PLM114

� Explain how the assembly and component scrap in the material master fieldaffect the production process

� Explain how the component scrap and operation scrap percentage in the billof material affect the production process

� Explain how the scrap in the percentage field in the routing affects theproduction confirmation process

� Describe and use production resources/tools in the routing

Unit ContentsLesson: Modeling Complex and Flexible Manufacturing Processes ... . .407

Exercise 22: Creating Alternative and Parallel Sequences .. . . . . . . . . .411Lesson: Modeling Alternative Manufacturing Processes ... . . . . . . . . . . . . . . .418

Exercise 23: Creating Alternative Routings and ProductionVersions... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421

Lesson: Reference Operation Sets... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431Exercise 24: Reference Operation Sets .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433

Lesson: Lead Time Scheduling and Material Master Updates.. . . . . . . . . . .441Exercise 25: Scheduling... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445

Lesson: Time Components, Reduction Possibilities in the Routing .. . . . .450Exercise 26: Time Elements of the Operation in Scheduling .. . . . . . . .457

Lesson: Trigger Points in the Routing... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464Procedure: Setting Up a Trigger Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466

Lesson: Scrap and Its Effects .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468Exercise 27: Scrap in Production ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473

Lesson: Production Resources/Tools ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .480Exercise 28: Creating and Assigning PRTs ... . . . . . . . . . . . . . . . . . . . . . . . . . .483


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PLM114 Lesson: Modeling Complex and Flexible Manufacturing Processes

Lesson: Modeling Complex and Flexible ManufacturingProcesses

Lesson OverviewIn this lesson you will discuss the use of parallel and alternative sequences tomodel complex and flexible manufacturing processes.


� Use parallel sequences in modeling complex manufacturing processes� Use alternative sequences in modeling flexible manufacturing processes

Business ExampleWithin the project team, you are responsible for routing management. You haveseveral products that undergo complex manufacturing steps. Due to the uniquenature of the process, several operations must occur simultaneously. In order todue this, you want to make use of parallel sequences in the routing.

In addition, you have some machines that are identical in nature. For capacityplanning purposes, you can switch jobs between the machines with little or noeffect on the subsequent operations. You would like to use alternative sequencesto model this flexible manufacturing opportunity.

Parallel SequencesYou use a single sequence to represent a simple linear series of production steps inproduction. If you want to represent a more complex series of production steps,you link several sequences with relationships to predecessors and successors.

In the simplest case a routing only has one sequence, the standard sequence.Every other sequence is either an alternative or a parallel sequence, depending onwhether its operations are performed as an alternative to the standard sequenceor in parallel (at the same time) with the standard sequence. Only routings canhave alternative sequences, parallel sequences can be created in both routingsand rate routings.

Parallel sequences are special types of overlapping operations that can be used invarious industries. A parallel sequence enables you to process several operationsat the same time. It is carried out at the same time as the corresponding section inthe standard sequence. It is a special form of overlapping operations.


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For example, in mechanical engineering for assembly lines with individualcomponent manufacturing, a parallel sequence allows for several individualcomponents from the BOM to be prepared as smaller units for final assembly.In the chemical industry, parallel sequences can be used to model analyticalprocesses that occur parallel to the production process.

Figure 153: Sequence Scheduling

An alignment key defines the start of the individual parallel sequences and,consequently, the position of the sequence buffers.

Only the first operation of a referenced operation set (or reference rate routing)that has not been unlocked can be used as a branch or as a return operation foralternative or parallel sequences. To use other operations within a referenceoperation set (or reference rate routing) for your parallel sequence, you mustfirst unlock the reference.

You can create parallel sequences in routings and rate routings. You cannot createthem in reference operation sets or reference rate routings

Alternative Sequences in RoutingsA linear sequence of operations that is an alternative to a sequence of operations inthe standard sequence.


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You use an alternative sequence for example, if:

� The production flow is different for certain lot-size ranges For instance youcan machine a work piece on conventional machine or on NC machines. ANC machine has a longer set-up time than a conventional machine. Howeverthe machining costs are considerably less. Therefore whether you use NCmachines will depend on the lot size.

� The production flow changes under certain business conditions. For instance,if you have a capacity problem, you have some production steps performedexternally by a vendor.

You can enter a lot-size range, so that the system automatically selects thealternative sequence if an order lies within this range. The lot size range of analternative sequence can differ from the one specified in the routing header.However, it must overlap at least partially with the lot size range in the routingheader.

Alternative sequences are linked to the standard sequence. Branch operations inthe standard sequence are ignored in the procedure.

Figure 154: Alternative Sequences

Only the first operation of a referenced operation set that has not been unlockedcan be used as a branch or as a return operation for alternative or parallelsequences. To use other operations within a reference operation set for youralternative sequence, you must first unlock the reference.

You can only create alternative sequences in routings. You cannot create them inreference operation sets, reference rate routings or rate routings.


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Exercise 22: Creating Alternative andParallel Sequences

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create a parallel sequence� Allocate components to an operation in the parallel sequence

Business ExampleIn your manufacturing process, you have steps in the process that are being donesimultaneously. You would like to model this complex manufacturing processusing parallel sequences.

Task:Create a routing with a parallel sequence for your finished material T-F## andallocate components to both the standard sequence and the parallel sequence.

1. First, create the standard sequence of the routing for the production ofmaterial T-F## in plant 1000, which consists of the five steps in the tablebelow. The routing should be creation status, valid from today's date, forproduction usage, and for lot sizes from 1 to 100,000 pieces. Use the data inthe table below to complete the routing information.

Primary Operation Data:

Opera-tion #

WorkCenter

ControlKey

Description

10 T-M## PP01 Material staging by picking list20 T-E## PP01 Preassemble pump components30 T-F## PP01 Final assembly of pump40 T-P## PP99 Deliver to stock

Standard Processing Times:




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2. Create the parallel sequence of the routing for the production of materialT-F## in plant 1000, which consists of the three steps in the table below. Usethe data in the table below to complete the routing information.

Parallel Sequence Operation Data:

Opera-tion #

WorkCenter

ControlKey

Description

10 T-V## PP01 Cut sheet metal20 T-V## PP01 Drill and tap holes30 T-L## PP01 Cover and paint


Activity Op 10 Op 20 Op 30Setup 10 Min 0 Min 15 MinMachine 10 Min 0 Min 5 MinLabor 0 Min 5 Min 5 Min

3. Assign material components from the BOM of T-F## to specific operationson the routing. Assign 100-700 to operation 10 of the parallel sequence and100-600, 100-130, and the non-stock item to operation 30 of the standardsequence.

Where will the other components that you haven't assigned be allocated?


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Solution 22: Creating Alternative andParallel SequencesTask:Create a routing with a parallel sequence for your finished material T-F## andallocate components to both the standard sequence and the parallel sequence.

1. First, create the standard sequence of the routing for the production ofmaterial T-F## in plant 1000, which consists of the five steps in the tablebelow. The routing should be creation status, valid from today's date, forproduction usage, and for lot sizes from 1 to 100,000 pieces. Use the data inthe table below to complete the routing information.


Opera-tion #

WorkCenter

ControlKey

Description

10 T-M## PP01 Material staging by picking list20 T-E## PP01 Preassemble pump components30 T-F## PP01 Final assembly of pump40 T-P## PP99 Deliver to stock




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b) Enter the material T-F## and plant 1000 and choose Enter .

c) Enter usage 1 for production, status 1 for creation phase, planner group0##, and lot size of 1 to 100,000 pieces.

d) Choose the Operations Overview icon and enterthe primary operation data from the table. Respond to any systemmessages that appear.

e) Select all operations and choose Details→ Operation from the menu.Enter the standard operation processing Times from the table andchoose to navigate to the next operation detail screen. Continueuntil all times have been entered and then choose to return to theoperation overview.

f) Save your routing.

2. Create the parallel sequence of the routing for the production of materialT-F## in plant 1000, which consists of the three steps in the table below. Usethe data in the table below to complete the routing information.

Parallel Sequence Operation Data:

Opera-tion #

WorkCenter

ControlKey

Description

10 T-V## PP01 Cut sheet metal20 T-V## PP01 Drill and tap holes30 T-L## PP01 Cover and paint




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Activity Op 10 Op 20 Op 30Setup 10 Min 0 Min 15 MinMachine 10 Min 0 Min 5 MinLabor 0 Min 5 Min 5 Min


b) Enter the material T-F## and plant 1000 and choose Enter .

c) Choose the Sequence Overview icon . Notice only the standardsequence is listed and this one is always numbered 0.

d) Choose the Create icon and select Parallel sequence.

e) Accept the default sequence number, enter Cut and paint sheetmetal as the description, select the alignment key Align with latestdates, and enter reference sequence 0 and return operation 20.

f) Choose the Operations Overview icon and enter theparallel sequence operation data from the table. Respond to any systemmessages that appear with No.

g) Select all operations and choose Details→ Operation from the menu.Enter the standard operation processing times from the table andchoose to navigate to the next operation detail screen. Continueuntil all times have been entered and then choose to return to theoperation overview.

h) Choose the Sequence Overview icon again. Noticethere are now two sequences: the standard sequence number 0 andthe parallel sequence number 1.

i) Select both sequences by clicking the button to the left of each and

choose the Operation Graphic icon .

j) Choose the Expand All icon to view the graphic details of yourrouting.

k) Choose to return to the sequence overview and save your routing.

3. Assign material components from the BOM of T-F## to specific operationson the routing. Assign 100-700 to operation 10 of the parallel sequence and100-600, 100-130, and the non-stock item to operation 30 of the standardsequence.



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Where will the other components that you haven't assigned be allocated?


b) Enter material T-F##, plant 1000, and choose Enter .

c) Chose the Component Allocation icon on the tool barand select the alternative 1 Bill of Material.

d) Select items 100-700 from the BOM that appears. Choose the New

Assignment icon on the tool bar .

e) You can enter sequence 1 operation 10 in the Activity field or choose

to select the operation from a list.

f) Choose Continue and repeat steps d) through e) for components100-300, 100-130, and the non-stock item, assigning them to operation30 of sequence 0.

g) Choose Save to save your routing and exit.

h) All other components that have not been assigned to any operation willdefault to the first operation of the standard sequence.


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Lesson Summary

You should now be able to:� Use parallel sequences in modeling complex manufacturing processes� Use alternative sequences in modeling flexible manufacturing processes


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Lesson: Modeling Alternative Manufacturing Processes

Lesson OverviewIn this lesson we will discuss the use of alternate routings to model alternativemanufacturing processes. You will also learn about the use of production versions.


� Model alternative manufacturing processes using alternative routings� Use production versions to model a very specific production process

Business ExampleWithin the project team, you are responsible for routing management. Several ofyour products require specific production cycles that are lot-size dependent. Tomodel this in SAP ERP, you must create routing alternatives for these products.

Alternative RoutingsDifferent production lot sizes may require alternative production methods forreasons of efficiency.

Figure 155: Routings


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PLM114 Lesson: Modeling Alternative Manufacturing Processes

The same material can be produced with different routings. The different routingscan be from different plants.

A single product with one BOM can be manufactured using different technologies.You might use an automatic assembly line for large quantities and a manualassembly line for small quantities. The end result, however, is the same materialfor both assembly lines.

A product can be made of different combinations of components, depending onthe quantity (lot size) to be manufactured. This type of product is represented byalternative BOMs. A product can have up to 1000 alternative BOMs that onlydiffer slightly, usually in terms of the component quantity.

In the above example, a single product is manufactured using differentmanufacturing technologies, which require different bills of material. Thisnecessitates not only different routings, but also different BOMs. Machine1 represents the older technology where the product is assembled from twopreviously assembled components. Machine 2 is a newer piece of equipmentsupporting the assembly of the product from four raw materials.

Each routing requires a BOM for the product representing the unique componentsconsumed by each manufacturing process. The selection of alternatives iscontrolled by the material master record and could be based on lot size, date,or production version.

Production VersionsIn the example illustrated below, a product is manufactured using two sets oftechnologies and methods. This necessitates different routings and differentBOMs.


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Figure 156: Production Versions

Version 0001 produces brackets for large order lots on an NC punching machine.The bracket is punched whole from a metal sheet.

Because it takes longer to set up a NC punching machine than the actual time ittakes for punching, version 0002 is used to produce small quantities of bracketswith another manufacturing process. This process requires strips of metal.

The appropriate alternative is selected using the production version in the materialmaster. The production version determines the manufacturing process accordingto the routing and BOM specified.

You can store multiple production versions for different lot size intervals in thematerial master. The group counter values differentiate the individual routings.


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Exercise 23: Creating Alternative Routingsand Production Versions

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create an alternative routing

Business ExampleYou have two different ways of manufacturing your product, T-B##. You needanother routing to model the manufacturing options.

Task 1:Create a second routing to model an alternate manufacturing process. Thismanufacturing process is only to be used for small lot sizes.

1. Create a second routing for the production of material T-B## in plant 1000,which consists of the five steps in the table below. The routing should becreation status, valid from today's date, for production usage, and for lotsizes from 1 to 100 pieces. Use the data in the table below to complete therouting information.


Opera-tion #

WorkCenter

ControlKey

Description

10 1112 PP01 Lathe casing20 1114 PP01 Drill holes30 1310 PP01 Preassembly40 1310 PP01 Final assembly50 1310 PP01 Deliver to stock


Activity Op 10 Op 20 Op 30 Op 40 Op 50Setup 10 Min 10 Min 0 Min 0 Min 0 MinMachine 30 Min 10 Min 0 Min 0 Min 0 MinLabor 30 Min 10 Min 5 Min 5 Min 10 Min



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2. What are the group number and group counter? How does this comparewith the other routing for T-B##?

Task 3:Assign components to operations on your alternate routing. Change the lot size soone routing is valid for small lot sizes 1-10 and the other is valid for large lot sizes11-100,000. Be sure to release both routings for production.

1. Assign component 100-120 to operation 30 and component 100-130 tooperation 40 on your new routing with group counter 2.

2. Change the lot size on routing with group counter 1 so it is valid for lot sizes11-100,000 and set the status to Released (general).

Task 4:Create production versions for the selection of routings.

1. Create a production version 0001 for the selection of BOMs and routings forT-B##. The production version should be valid from today until 12/31/9999,for lot sizes 11 to 100,000 pc. Use task list type routing with your routing forT-B## group counter 1, and use BOM alternative 1 with usage 1.

2. Create another production version 0002 for the selection of BOMs androutings for T-B##. The production version should be valid from today until12/31/9999, for lot sizes 1 to 10 pc. Use task list type routing with yourrouting for T-B## group counter 2, and use BOM alternative 1 with usage 1.

3. For the system to select your routings by production versions for thismaterial, you will need to change the Selection Method field on the MRP4view of the material master.


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Solution 23: Creating Alternative Routingsand Production VersionsTask 1:Create a second routing to model an alternate manufacturing process. Thismanufacturing process is only to be used for small lot sizes.

1. Create a second routing for the production of material T-B## in plant 1000,which consists of the five steps in the table below. The routing should becreation status, valid from today's date, for production usage, and for lotsizes from 1 to 100 pieces. Use the data in the table below to complete therouting information.


Opera-tion #

WorkCenter

ControlKey

Description

10 1112 PP01 Lathe casing20 1114 PP01 Drill holes30 1310 PP01 Preassembly40 1310 PP01 Final assembly50 1310 PP01 Deliver to stock




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Activity Op 10 Op 20 Op 30 Op 40 Op 50Setup 10 Min 10 Min 0 Min 0 Min 0 MinMachine 30 Min 10 Min 0 Min 0 Min 0 MinLabor 30 Min 10 Min 5 Min 5 Min 10 Min


b) Enter the material T-B## and plant 1000 and choose Enter .

c) In the Create routing overview screen, choose the Create icon .

d) The group counter defaults to the next available number, in this case 2.Enter usage 1 for production, status 1 for creation phase, planner group0##, and lot size of 1 to 10 pieces.

e) Choose the Operations Overview icon and enterthe primary operation data from the table. Respond to any systemmessages that appear.

f) Select all operations and choose Details→ Operation from the menu.Enter the standard operation processing times from the table and chooseto navigate to the next operation detail screen. Continue until all

times have been entered and then choose to return to the operationoverview and save your routing.




b) Enter T-B## and plant 1000 and choose .

c) On the Routing overview screen, select the routing with group counter2 and choose .

2. What are the group number and group counter? How does this comparewith the other routing for T-B##?

a) The group number will vary but should be a number beginning with50000____ and the group counter should be 2.

b) The group number is the same as the group number for the other routingfor T-B## but the group counter is different.



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Task 3:Assign components to operations on your alternate routing. Change the lot size soone routing is valid for small lot sizes 1-10 and the other is valid for large lot sizes11-100,000. Be sure to release both routings for production.

1. Assign component 100-120 to operation 30 and component 100-130 tooperation 40 on your new routing with group counter 2.



c) On the Routing overview screen, select the routing with group counter

2 and choose .

d) Select item T-T2## from the BOM that appears. Choose the New

Assignment icon on the tool bar .

e) You can enter operation 30 in the Activity field or chooseto select the operation from a list.

f) Choose Continue .

g) Repeat steps c) through e) to assign item T-T3## to operation 40.




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2. Change the lot size on routing with group counter 1 so it is valid for lot sizes11-100,000 and set the status to Released (general).



c) On the Routing overview screen, select the routing with group counter1 and choose .

d) Change the lot size fields to 11 to 100,000.

e) Change the status to 4 Released (general).

f) Click the Routings icon to return to the Routing overview.

g) Deselect the routing with group counter 1, select the routing with groupcounter 2, and choose again.

h) Change the status to 4 Released (general) and make sure the lot sizeis for 1 to 10.

i) Choose Save to save your routing and exit.



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Task 4:Create production versions for the selection of routings.

1. Create a production version 0001 for the selection of BOMs and routings forT-B##. The production version should be valid from today until 12/31/9999,for lot sizes 11 to 100,000 pc. Use task list type routing with your routing forT-B## group counter 1, and use BOM alternative 1 with usage 1.

a) Choose Logistics→ Production→ Master Data→ ProductionVersions or use transaction code C223.

b) Delete all entries in the Selection condition fields exceptMaterialT-B## and Plant 1000. Then choose Enter .

c) You should now be able to enter the data for material T-B##,production version 0001, and text Normal Production. Byhitting ENTER twice to work through the warning, the valid dateswill default.

d) You can continue to work in the table or you can double-click on theproduction version number 0001 and work in the detail screen to enterdata, which might make data entry easier.

e) Enter lot size 11 to 100,000 pc.

f) In the Task List section, choose Routing from the list for Task List Type.

g) Enter your routing's group number in the Group field. If you don'tknow the group number, you can find the correct routing by usingthe F4 search function or the drop-down list. Choose tab C: Searchusing material and choose Continue . Be sure to choose the routingwith group counter 1.

h) In the Bill of Material section, enter alternative BOM 1 and usage 1.

i) Now you can close the detail screen by choosing .



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2. Create another production version 0002 for the selection of BOMs androutings for T-B##. The production version should be valid from today until12/31/9999, for lot sizes 1 to 10 pc. Use task list type routing with yourrouting for T-B## group counter 2, and use BOM alternative 1 with usage 1.

a) Choose Logistics→ Production→ Master Data→ ProductionVersions or use transaction code C223.

b) Delete all entries in the Selection condition fields exceptMaterialT-B## and Plant 1000. Then choose Enter .

c) Now you should be able to enter the data for material T-B##,production version 0002, and text Small Lot SizeProduction. By hitting ENTER twice to work through the warning,the valid dates will default.

d) You can continue to work in the table, or you can double-click on theproduction version number 0002 and work in the detail screen to enterdata, which might make data entry easier.

e) Enter lot size 1 to 10 pc.

f) In the Task List section, choose Routing from the list for Task List Type.

g) Enter your routing's group number in the Group field. If you don'tknow the group number, you can find the correct routing by usingthe F4 search function or the drop-down list. Choose tab C: Searchusing material and choose Continue . Be sure to choose the routingwith group counter 2.

h) In the Bill of Materiall section, enter alternative BOM 1 and usage 1.

i) Now you can close the detail screen by choosing .

j) Be sure to save your production versions.



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3. For the system to select your routings by production versions for thismaterial, you will need to change the Selection Method field on the MRP4view of the material master.

a) Choose Logistics→ Production→Master Data→Material Master→Material→ Change→ Immediately or use transaction code MM02.

b) Enter material T-B## and press ENTER.

c) Select the MRP 4 view from the list and press ENTER.

d) Enter plant 1000 and press ENTER.

e) In the BOM explosion/dependent requirements section, change theSelection Method field to 2 Selection by production version or 3Selection only by production version.

f) Choose Save. Now the system will use the production versions forselection of the BOM and routing for this material.


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Lesson Summary

You should now be able to:� Model alternative manufacturing processes using alternative routings� Use production versions to model a very specific production process


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PLM114 Lesson: Reference Operation Sets

Lesson: Reference Operation Sets

Lesson OverviewIn this lesson you will learn about reference operation sets and how to use them.You will create a reference operation set and reference it in your routing. You willalso use a reference operation set as a template for creating routings.


� Utilize reference operation sets to minimize routing maintenance� Create a reference operation set� Use a reference operation set in a routing� Use a reference operation set as a template to create a routing

Business ExampleThe inspection process for several different pumps consists of the same steps. Youneed an efficient way to maintain these steps on multiple routings. Your grouprouting uses the same steps, but they have different standard values. You wantto use these inspection steps as a template as an efficient way of creating yourgroup routing.

Reference Operation SetsA reference operation set is a standard operation sequence for performing a taskthat is frequently used. Creating a reference operation set provides an efficientway to maintain this set of operations. It can be used either as a reference or asa template when you create a routing.


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Figure 157: Reference Operation Sets

The reference to a reference operation set is created in the operation overview.The operations in the reference operation set are renumbered to fit into the routing.

A reference operation set does not allow parallel or alternative sequences.Material components, PRTs, and trigger points can be assigned to an operation ina reference operation set. Any assignments to a reference operation set will becopied into the routing. Any change made to a reference operation set will updateall routings that use it.

A reference operation set can be created manually, or a routing or referenceoperation set can be used as a template. If you copy from a routing, only thebasic sequence is copied. If you copy from a reference operation set, there isno reference.


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Exercise 24: Reference Operation Sets

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create a reference operation set� Use a reference operation set in a routing� Use a reference operation set as a template to build a routing

Business ExampleIn your production process, there is an inspection process that is common to manyroutings. Since the steps and standard values are identical for all routings, youneed an efficient way to maintain this data. In your group routing, the steps areidentical but the standard values are different. You need an efficient way to buildthese steps into your routing but still be able to change the standard times.

Task 1:Create a reference operation set for the inspection of manufacturing products.

1. Create a reference operation set for the inspection of your manufacturingproducts. This will be an in-process inspection to be used for productionwith status Release (general). Assign it to your planner group 0##, use thedescription In-process inspection ##, and enter the data in the table below.

Operation Work Center Control Key Description Labor10 R-K## PP01 Test

Inspection10 Min

20 R-P## PP01 Examineafter testing

5 Min

Task 2:Assign the reference operation set to your routing.

1. Change your routing for T-F## to include the reference operation set youjust created. This inspection needs to take place just prior to final assembly,and again before delivery to stock.



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Task 3:Use your reference operation set to build inspection steps into your group routing.

1. Your group routing PUMP## also needs the same inspection steps, but sincethe standard values are different in this routing you will use the referenceoperation set to insert the operations and then unlock the reference so youcan change the standard values for this routing. The reference operation setshould be inserted at operations 35 and 45. Only unlock the reference at 35,since those are the only standard values that are different.

Task 4:New inspection requirements have increased the standard time at inspection workcenter R-K## from 10 min to 15 min. Change your reference operation set toreflect this new time.

1. Change the standard value of operation 10 in your reference operation setfrom 10 min to 15 min and update all routings to which it is assigned. Whatdoes the warning message mean?

2. Display your routing for T-F## and plant 1000 to make sure the changeswere made.

3. Display your group routing PUMP## to check if the changes have also beenmade there. Was the standard value for operation 45 changed? Was thestandard value for operation 35 changed? Why or why not?


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Solution 24: Reference Operation SetsTask 1:Create a reference operation set for the inspection of manufacturing products.

1. Create a reference operation set for the inspection of your manufacturingproducts. This will be an in-process inspection to be used for productionwith status Release (general). Assign it to your planner group 0##, use thedescription In-process inspection ##, and enter the data in the table below.

Operation Work Center Control Key Description Labor10 R-K## PP01 Test

Inspection10 Min

20 R-P## PP01 Examineafter testing

5 Min

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Reference Operation Sets→ Create or use transactioncode CA11.

b) Choose Enter without entering any data in the initial screen.

c) Enter the description In-process inspection ##, usage 1,status 4, planner group 0##, lot size 1 to 100000 pc, and choose theOperation overview icon .

d) Enter the data from the table and save. Make note of the systemassigned group number that appears in the status bar when you save.



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Task 2:Assign the reference operation set to your routing.

1. Change your routing for T-F## to include the reference operation set youjust created. This inspection needs to take place just prior to final assembly,and again before delivery to stock.



c) From the operation overview, choose Extras→ Reference→ Create.

d) Enter operation 25 and the group number of the reference operationset you recorded earlier. If you don't have the group number, you cansearch possible entries with the drop-down list. Choose S: Referenceoperation sets and enter your planner number 0##. Then chooseEnter and your reference operation set will appear on a list for you tochoose it.

e) Repeat step d for operation 35.

Note: Notice the operations of the reference operation set aredisplay only and cannot be changed here. Changes will need tobe made in the reference operation set. All routings to which itis assigned will then be automatically updated.

Task 3:Use your reference operation set to build inspection steps into your group routing.

1. Your group routing PUMP## also needs the same inspection steps, but sincethe standard values are different in this routing you will use the referenceoperation set to insert the operations and then unlock the reference so you



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can change the standard values for this routing. The reference operation setshould be inserted at operations 35 and 45. Only unlock the reference at 35,since those are the only standard values that are different.


b) Be sure the material number is blank, enter plant 1000, groupPUMP##, and choose Enter .

c) From the operation overview, choose Extras→ Reference→ Create.

d) Enter operation 35 and the group number of the reference operationset you recorded earlier. If you don't have the group number, you cansearch possible entries with the drop-down list. Choose S: Referenceoperation sets and enter your planner number 0##. Then choose Enterand your reference operation set will appear on a list for you to select it.

e) Repeat step d using operation 45.

f) Select operation 35 and choose Extras→ Reference→ Unlock.

g) Now change the standard times of operations 35 and 36 to 5 Minand 3 Min, respectively.

Note: Be aware that since this reference has been unlocked,any changes to the reference operation set will not updateoperations 35 and 36.



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Task 4:New inspection requirements have increased the standard time at inspection workcenter R-K## from 10 min to 15 min. Change your reference operation set toreflect this new time.

1. Change the standard value of operation 10 in your reference operation setfrom 10 min to 15 min and update all routings to which it is assigned. Whatdoes the warning message mean?

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Reference Operation Sets→ Change or use transactioncode CA12.

b) Enter the group number of your reference operation set or search for itas previously indicated and choose Enter .

c) Acknowledge the warning message that appears. This message meansthat upon saving, any changes made to the reference operation set willupdate all routings to which it is assigned.

d) Double-click on operation number 10 to go to the details of theoperation. Change the 10 Min of labor time to 15 Min.

e) Save the reference operation set.

2. Display your routing for T-F## and plant 1000 to make sure the changeswere made.



c) Double-click on operation number 25 and check the details to be surethe labor time is now 15 Min.

d) Repeat this for operation number 35.



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3. Display your group routing PUMP## to check if the changes have also beenmade there. Was the standard value for operation 45 changed? Was thestandard value for operation 35 changed? Why or why not?


b) Be sure the material number is blank, enter plant 1000, groupPUMP##, and choose Enter .

c) Double-click on operation number 45 and check the details to be surethe labor time is now 15 Min. Yes, this standard value was changedwhen the reference operation set was saved.

d) Repeat this for operation number 35. No, the standard values herewere not changed because the link back to the reference operation setwas broken when it was unlocked.


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Lesson Summary

You should now be able to:� Utilize reference operation sets to minimize routing maintenance� Create a reference operation set� Use a reference operation set in a routing� Use a reference operation set as a template to create a routing


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PLM114 Lesson: Lead Time Scheduling and Material Master Updates

Lesson: Lead Time Scheduling and Material MasterUpdates

Lesson OverviewThis lesson describes the details of lead time scheduling and updating in-houseproduction time in the material master.


� Describe in detail the concept of lead time scheduling and updating in-houseproduction time in the material master

� Identify the data used in lead time scheduling� Explain how the SAP ERP system uses the data to determine the lead time

schedule� Update the material master record of a material from the routing

Business ExampleAs a member of the project team, you are responsible for the precise timescheduling of your products. To ensure this can happen, you need to first fulfillthe following prerequisites:

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

Lead Time Scheduling and Material Master UpdatesMaterial requirements planning explodes a material's BOM, generates plannedorders or purchase requisitions for the components to be procured, and calculatesbasic order dates. Basic order dates (planned dates) are calculated using eitherthe lot-size-independent or lot-size-dependent in-house production time forinternally procured materials, or the planned delivery time for externally procuredmaterials. The in-house production time for a material can be calculated usinglead time scheduling of a routing without an order, and can then copied to thematerial master.


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Figure 158: Calculation of Basic Dates

Production planning has two types of scheduling that are implemented in differentways: basic date scheduling and lead time scheduling.

Figure 159: Scheduling in Production Planning

To ensure smooth material requirements planning, it is absolutely necessary toschedule a routing and to update the material master with the scheduling results. Ifmaterial requirements planning (MRP) is carried out without lead time scheduling(as shown in the top half of the figure), capacity requirements are not determinedfor planned orders.


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Production orders are always scheduled using lead time scheduling for theoperations. A production order always contains both sets of dates (basic dates andbaseline dates). Baseline dates are relevant for production.

You can also use lead time scheduling to determine capacity requirements forplanned orders in MRP.

Figure 160: Scheduling of In-House Production Time

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


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Exercise 25: Scheduling

Exercise ObjectivesAfter completing this exercise, you will be able to:� Schedule a routing� Analyze the schedule of a routing using a table and Gantt chart� Update the basic dates in the material master from the schedule of the routing

Business ExampleIt is important to ensure that the production schedule is accurate. Therefore,you need to analyze the scheduling of routings before they are used to createproduction order. In addition, to ensure that basic date and lead time schedulingare synchronized, you will need to schedule the routing and update the materialmaster record.

Task 1:Schedule your routing to make sure the production schedule is accurate. Displaythe schedule using an object overview and a Gantt chart.

1. Schedule your routing for the pump T-F## using forward scheduling fromtoday's date with a lot size of 100 pc. Use the operation segments overviewvariant and the Gantt chart to view your schedule.

Task 2:Schedule your routing and update the material master record with the scheduledata.

1. Schedule your routing for the pump T-F## using forward scheduling fromtoday's date with a lot size of 100 pc. Use the operation segments overviewvariant and update the material master record.

2. Update the material master record with the schedule data.

3. Now check the material master to be sure it was updated.


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Solution 25: SchedulingTask 1:Schedule your routing to make sure the production schedule is accurate. Displaythe schedule using an object overview and a Gantt chart.

1. Schedule your routing for the pump T-F## using forward scheduling fromtoday's date with a lot size of 100 pc. Use the operation segments overviewvariant and the Gantt chart to view your schedule.



c) From the menu, choose Extras→ Scheduling→ Schedule.

d) Enter today's date as the start date, select forward scheduling asthe scheduling type, enter 100 for the lot size (these should all default),and choose Continue .

e) Select the overview variant 000000000001 Operation segments andchoose Continue .

f) Make sure all your operations are scheduling correctly in the schedulingoverview table that appears. Make any necessary corrections andschedule the routing again.

g) Click the Gantt chart icon and view the schedule graphically.



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Task 2:Schedule your routing and update the material master record with the scheduledata.

1. Schedule your routing for the pump T-F## using forward scheduling fromtoday's date with a lot size of 100 pc. Use the operation segments overviewvariant and update the material master record.






f) In the Scheduling Overview, select the Scheduling Results icon

.

g) In the dialog box that appears, you can compare the scheduling resultswith the current material master settings. Choose the Update mat.

master button in the dialog box.

h) You should receive a message box that says �Scheduling data markedfor material master update.�

2. Update the material master record with the schedule data.

a) Choose Logistics→ Production→ Master Data→ Routings→ Extras→ Material Master→ Update Material Master or use transactioncode CA96.

b) Enter plant 1000, production planner 0##, and choose Enter .

c) Select your material from the list and choose the Update mat. master

icon on the tool bar.



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3. Now check the material master to be sure it was updated.

a) Choose Logistics→ Production→Master Data→Material Master→Material→ Display→ Display Current or use transaction code MM03.

b) Enter material T-F## and choose Enter .

c) Select the Work Scheduling view and choose .

d) Enter plant 1000 and choose .

e) You should see the results of the update in the In-house productiontime in days section.


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Lesson Summary

You should now be able to:� Describe in detail the concept of lead time scheduling and updating in-house


schedule� Update the material master record of a material from the routing


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Lesson: Time Components, Reduction Possibilities inthe Routing

Lesson OverviewIn this lesson you will look at the various options for detailed scheduling includinginteroperations times, continuous input/ouput, and splitting operations in multiplecapacity work centers.


� Demonstrate the use of interoperation times in the routing for job shoprelated environments

� Demonstrate the use of Overlapping for a continuous manufacturing process� Demonstrate the use of splitting for multi-capacity work centers.

Business ExampleAs a member of the project team, you are responsible for the precise timescheduling of your products. In order to do this you need to model the criticalpath and any possible interoperation or float time that might occur during anormal production. To ensure this can happen, you need to review the use ofinteroperation times, overlapping, and splitting in the routing operations.

Modeling Standard Float Time in the RoutingSince malfunctions and other disturbances in the production process can neverbe fully prevented, the system carries out scheduling using a float before and afloat after production. The floats before and after production are defined in thematerial master record using a scheduling margin key.

The two float times serve different purposes:

Float before productionThe float before production has the following two functions in the order: Itcan compensate for delays in the staging of the material components or ifthere is a capacity bottleneck at the work centers involved, you can movethe production dates forward in the future. In this way it serves as a floatfor capacity leveling. The system calculates the scheduled start by addingthe float before production to the basic start date.


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PLM114 Lesson: Time Components, Reduction Possibilities in the Routing

Float after productionThe float after production is used in the order to compensate for unexpectedinterruptions in the production process. It prevents a delay of the scheduledfinish. The system calculates the scheduled finish by subtracting the floatafter production from the basic finish date.

Figure 161: Time Elements in Lead Time Scheduling

The order float can be predefined and is controlled by the scheduling margin key.In Customizing, the scheduling margin key is defined and then assigned on theMRP 2 view of the material master record.

The duration of an operation consists of a maximum of five time components:

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

Queue Time

In addition to the floats before and after production, you can define an operationfloat in the form of a queue time. The queue time is used to compensate formalfunctions and delays within an operation. The queue time is the intervalbetween the earliest and latest dates of the operation (see the following figure).During each scheduling run, the system calculates the earliest and the latest datesfor the individual operation segments. You can maintain the queue time in boththe work center and operation. However, the system only schedules with the


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queue time in the work center if you have not maintained the queue time in theoperation. If the lead time of an operation must be reduced, the system can shortenthe standard queue time as far as the minimum queue time.

Setup Time

The setup time is the time needed to prepare the work center for operations toperform there. The setup time is part of the lead-time.

Processing Time

The processing time is the time needed to process a material in an operation. Theprocessing time is dependent on the order quantity, and does not contain a setup orteardown time. It is part of the execution time.

Teardown Time

The teardown time is the time needed to restore a work center to its normal stateafter operations have been processed. The teardown time is part of the executiontime.

Wait Time

The wait time is the time between the end of the execution time and the start ofmove time. In the SAP system, types of wait time are:

� Maximum� Minimum

In scheduling, only the minimum wait time is taken into account. The maximumwait time is used for information.

Using the teardown/wait simul. indicator in the interoperation times section of theOperation Details screen, you can specify whether teardown and wait are to beconsidered as simultaneous or consecutive operation segments in scheduling. Ifteardown and wait times are simultaneous, the lead time of the operation is reduced

The wait time is scheduled without taking the factory calendar into account. Thismeans that it can be scheduled daily from 0.00 to 24.00.

Move Time

In addition to these operation segments, you can define a move time. The movetime is the time needed to move a material from one work center to the next one.Move time is always between two operations and is assigned to the precedingoperation.

You can maintain the move time in the individual operations or in Customizingper location group in the move time matrix. In the interoperation times section ofthe Operation Details screen, you can maintain a minimum and a standard movetime. If reduction measures are carried out, the system schedules the operations


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using the minimum move time. The system determines the move time using themove time matrix, only if you do not maintain move times in the interoperationtimes section of the Operation Details screen.

You can combine work centers which are in close proximity to each other intolocation groups. You can define location groups in Customizing and assign awork center to a location group on the Scheduling screen of the work center. Inthe move time matrix, you can specify planned values for the move time withina location group or from one location group to another. For each entry, you canspecify a minimum and a standard move time.

The operation segments and the move time are used to determine the executiontime, lead time and interoperation time of an operation.

The material requirement is scheduled from the earliest start date (you can changethis in Customizing).

The capacity requirement can be displayed on the earliest or latest start datedepending on the customizing settings.

For external operations, the delivery time is specified in days. These operationsare scheduled based on the Gregorian calendar.

Figure 162: Time Components and Their Origins

You maintain time elements for lead time scheduling in various places withinthe PP application.

It is important to make the correct settings and use the system properly forsuccessful scheduling.


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The interoperation time in the material master is calculated from:

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

Modeling Operation Splits in the RoutingAn operation is split if it is carried out on several machines or by several personsat the same time. Splitting an operation has the following effects on the operationdates: The processing time/execution time becomes shorter. Setup and teardownmust be carried out more than once for the operation.

Modeling Continuous Manufacturing as with MultipleOperationsTo reduce the lead time of a routing or production order you can overlap operations.This means that an operation starts before the previous operation has finished

You can define for each individual operation whether it should overlap with thenext consecutive operation and in what way. To do this you can set the followingindicators:

� Required overlapping

This means the operations always overlap

� Optional overlapping

This means the operations overlap if scheduling uses a reduction level thatallows overlapping

� Flow manufacturing

This means the system extends the lead time of all operations, that overlapusing flow manufacturing, to the same length as the lead time of the longestof these operations. As with required overlapping, the operations alwaysoverlap

For every type of overlapping you can

� Define a minimum overlap time which only allows overlapping after aparticular minimum limit has been reached.

� Define a minimum send-ahead quantity to ensure that the operation isperformed for a particular minimum quantity of the material to be produced,before the next operation starts.


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Reduction MeasuresThe system can carry out reduction measures in lead time scheduling for orders.If the lead time calculated in scheduling is longer than the time between thebasic dates, the system will carry out reduction measures to reduce the lead time.Reduction is carried out step by step. After each reduction measure, the systemchecks whether the calculated dates are within the basic dates. If this is the case,no further reduction measures are carried out.

Figure 163: Reduction Process in Scheduling Routings

You can assign a reduction strategy to each operation in the interoperationtimes section of the Operation Details screen. This strategy specifies how manyreduction levels may be applied to an operation (maximum of six levels) whichreduction measures are carried out at the individual levels.

The order is rescheduled after every reduction level. To improve performance it isrecommended that you keep the number of reduction steps to a minimum.


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Figure 164: Reduction Strategy

You can set the time elements that can be reduced as well as the reduction strategyin Customizing (for each order category and planner group).

The following reduction measures can be carried out with respect to the operation:Reduction of the queue time:

� For each reduction level, you can specify the percentage by which the queuetime is to be reduced. However, you cannot reduce to a value smaller thanthe minimum queue time.

� Reduction of the execution time by splitting - Dividing an operation betweenseveral people or machines results in a reduction of the execution time.

� Reduction of the lead time by overlapping - You can reduce the overall leadtime of an order by overlapping operation processing.

� Reduction of the move time - You can reduce the standard move time as faras the minimum move time.

� The minimum wait time cannot be reduced.

You can also specify reduction for the floats before and after production in theorder or in Customizing for each plant, order type and planner group.

In order to reduce the lead time of a routing with parallel sequences, you specifythat reduction is only carried out on operations, if a reduction in their executiontime leads to a reduction in the overall lead time of the order. The sequence ofsuch operations in the routing with parallel sequences forms the "critical path". Ifapplying reduction measures to an operation, would not lead to an overall leadtime reduction, this operation is not reduced. If a routing does not contain parallelsequences, there is no critical path. All operations are then reduced, irrespective ofwhether you have selected reduction via the critical path or not.


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Exercise 26: Time Elements of theOperation in Scheduling

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create an operation in a routing that splits the workload over several

machines� Create operations that model continuous output and overlap the previous

operation to reduce lead time

Business ExampleOne operation in your routing to produce pumps has several machines that cando the work. You need to be sure the routing will schedule the workload acrossall machines. As part of a lean manufacturing initiative at your company, you arerequired to perform single-piece production.

Task 1:Change the operation on your routing to require splitting the workload acrossall machines.

1. Schedule your routing for the pump T-F## using forward scheduling fromtoday's date with a lot size of 100 pc. Use the operation segments overviewvariant and the Gantt chart to view your schedule. What is the processing(Edit) time of operation 20? What is the lead time of the routing in days?

2. Operation 20 in your routing, preassembly of the pump, has a work centerwith three machines (three individual capacities). Change this operation torequire splitting across all three machines.

3. Schedule your routing again for the pump T-F## using forward schedulingfrom today's date with a lot size of 100 pc. Use the operation segmentsoverview variant and the Gantt chart to view your schedule. Compare thedifferences in scheduling. What is the processing (Edit) time of operation20? What is the lead time of the routing in days?

Task 2:Due to a lean manufacturing initiative in your company, you are required touse single-piece manufacturing. Change your routing to accommodate thisrequirement.

1. Change your routing so every operation requires overlapping with one piecesend-ahead quantity.



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Solution 26: Time Elements of theOperation in SchedulingTask 1:Change the operation on your routing to require splitting the workload acrossall machines.

1. Schedule your routing for the pump T-F## using forward scheduling fromtoday's date with a lot size of 100 pc. Use the operation segments overviewvariant and the Gantt chart to view your schedule. What is the processing(Edit) time of operation 20? What is the lead time of the routing in days?






f) The processing time (labeled Edit) for operation 20 is 1000 min.

g) In the Scheduling Overview, select the Scheduling Results icon

. Make note of the lead time in days for the entirerouting.

h) Click the Gantt chart icon and view the schedule graphically.



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2. Operation 20 in your routing, preassembly of the pump, has a work centerwith three machines (three individual capacities). Change this operation torequire splitting across all three machines.



c) Double-click on operation number 20 to go to the details of theoperation.

d) Scroll down to the splitting section and select the indicator for Requiredsplitting. You need not enter the number of splits, but let it default tothe number of individual capacities.







f) The processing time (labeled Edit) for operation 20 is 333.3 min.

g) In the Scheduling Overview, select the Scheduling Results icon

. Make note of the lead time in days for the entirerouting.

h) Click the Gantt chart icon and view the schedule graphically.



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Task 2:Due to a lean manufacturing initiative in your company, you are required touse single-piece manufacturing. Change your routing to accommodate thisrequirement.

1. Change your routing so every operation requires overlapping with one piecesend-ahead quantity.



c) Select all operations and choose Details→ Operations to go to thedetails of the operation.

d) Scroll down to the overlapping section, select Required overlapping,and enter 1 pc in the min. send-ahead qty.

e) Choose to go to the next operation and repeat the settings until alloperations have been performed.

f) Click the green back arrow to get back to the operations overview

and then choose the Sequence overview icon to seethe other sequences.

g) Select sequence 1, the parallel sequence, and choose the Operations

overview icon .

h) Select all operations and choose Details→ Operations to go to thedetails of the operation.

i) Scroll down to the overlapping section, select Required overlapping,and enter 1 pc in the min. send-ahead qty.

j) Choose to go to the next operation and repeat the settings until alloperations have been performed.

k) Save your changes.



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d) Enter today's date as the start date, select Forward as thescheduling type, enter 100 for the lot size (these should all default),and choose Continue .


f) In the Scheduling Overview, select the Scheduling Results icon . Makenote of the lead time in days for the entire routing.

g) Choose the Gantt chart icon and view the schedule graphically.


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Lesson Summary

You should now be able to:� Demonstrate the use of interoperation times in the routing for job shop

related environments� Demonstrate the use of Overlapping for a continuous manufacturing process� Demonstrate the use of splitting for multi-capacity work centers.

Related Information

� [Enter an optional reference using the URL or CrossReference tag toadditional information that learner may find useful. Examples includewebsites or whitepapers. Delete if not used.]


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Lesson: Trigger Points in the Routing

Lesson OverviewIn this lesson you will learn how trigger points can be used to trigger actions inthe production order. You will use a standard trigger point to create a specifictrigger point for your routing.


� Describe the use of trigger points to streamline and automate severaladministrative processes

Business ExampleAs a production planner/scheduler, you are responsible for modeling theproduction process of several materials in SAP ERP. Several of your assemblesundergo a very sophisticated manufacturing process. Due to the complex nature ofthe process, it often yields product that needs to be reworked during the process,as well as after the final process is complete. Your company has asked you to finda way to automate the rework business process at the time rework is reportedduring production confirmation. You need to investigate trigger points as a way ofautomating the rework process.


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PLM114 Lesson: Trigger Points in the Routing

Defining Trigger PointsTrigger points are assigned to operations in a routing to trigger certain functionsin the production order at a later time. Trigger points can trigger functions whenan operation�s status changes or when an operation is confirmed. The personmaking the confirmation decides if the function is triggered when the operation isconfirmed. Trigger points can trigger the following functions:

� Release succeeding operations. You can release all operations that follow theoperation which has the trigger point assigned to it.

� Release up to stop indicator. You can release all operations up to andincluding the next operation for which the RelStop indicator is set.

� Release preceding operations. You can release all operations before theoperation with the trigger point assigned to it.

� Create order by copying. You can create a new order without reference toa material by copying a reference operation set.

� Insert reference operation set. You can insert a reference operation set intoan existing order. To do this, you must enter the operations between whichyou would like to insert the reference operation set.

� Start workflow task (for example, send mail to a user)

Standard trigger points can be copied to create new trigger points. If you copy astandard trigger point to create a trigger point, the system automatically transfersall necessary data from the standard trigger point into the trigger point you arecreating. This reduces the time and work involved in creating a trigger point.

You can combine several standard trigger points into a trigger point group. If youcopy from a trigger point group, the system automatically transfers all standardtrigger points in the trigger point group to the operation. Using trigger pointgroups considerably reduces the time and work involved in creating trigger points.You can maintain trigger point groups in Customizing.


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Setting Up a Trigger Point

1. Choose Logistics→ Production→ Master Data→ Standard Trigger Points→ Standard trigger pt→ Create or use transaction CO31.

2. Enter the Std Triggerpoint name and description.

3. Assign a usage and group if you want.

4. In Usage, select the function the trigger point should serve: TrigPointFunctsor Release Stop.

� TrigPointFuncts: The trigger point triggers the functions you enteredon the detail screen for trigger points (for example, release operation orinclude reference operation set).

� Release Stop: The operation is the last in a series of operations releasedby the trigger point. If the function release up to stop was triggered ina previous operation, all subsequent operations are released up to theoperation with the RelStop indicator

5. Assign a User Status profile and press ENTER.

6. Select the function the trigger point should execute, along with the system oruser status and how it is initiated.

7. In trigger point parameters, assign the group number and counter or anyadditional data that is needed.


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PLM114 Lesson: Trigger Points in the Routing

Lesson Summary

You should now be able to:� Describe the use of trigger points to streamline and automate several

administrative processes


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Lesson: Scrap and Its Effects

Lesson OverviewIn this lesson you will look at the different ways to define scrap in the SAP ERPsystem, and what effect they have on planning.


� Explain how the assembly and component scrap in the material master fieldaffect the production process

� Explain how the component scrap and operation scrap percentage in the billof material affect the production process

� Explain how the scrap in the percentage field in the routing affects theproduction confirmation process

Business ExampleAs a production planner/scheduler you are responsible for meeting customerservices demands placed on you by the forecast and sales orders. Several of theproduction processes that you are responsible for scheduling are quite complexand yield loss is quite high. To assure that you deliver enough good production toinventory, you need to factor in these losses ahead of time. You want to examinethe options in the bill of material, the material master, and the routing so you canproperly model your scrap allowances.

Calculating ScrapYou can calculate and plan the scrap quantity that will result from production.These scrap quantities are then included in the planning run and in the calculationof production costs. Which calculation the system uses depends on the settings inthe material master record, the BOM, or the routing. The scrap quantity is settledagainst the net requirements quantity. Scrap is used for material requirementsplanning and product costing. The three scrap calculation procedures supportedby the system are:

� Assembly scrap� Component scrap� Operation scrap


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PLM114 Lesson: Scrap and Its Effects

Figure 165: Scrap Categories and Their Effect

Assembly ScrapYou use this function to plan the scrap that results from the production of anassembly. Assembly scrap increases the order quantity of the assembly and,subsequently, increases the order quantity for each component in the BOM of theassembly by adjusting the quantity of the dependent requirements generated duringthe MRP run. The system automatically increases the quantity to be produced bythe percentage of scrap. However, the system always uses the estimated yield forthe availability calculation for the assembly. Furthermore, the estimated yield ofthe assembly is always displayed in the MRP list or in the stock/requirements list.

Assembly scrap is only used when the material is an assembly. Reasons forassembly scrap include inadequate quality or bad working conditions, such asheat, cold, or dampness.

Component ScrapYou use this function to plan the scrap of a component that may break duringproduction of an assembly. You can define component scrap in two places:

� In the BOM on the Item Detail Screen: General Data (quantity data section).This component scrap is only relevant for the individual BOM.

� In the material master (MRP 4 view) in the Component scrap field. Thiscomponent scrap is relevant for all BOMs.


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The component scrap quantity maintained for a material component in the BOMhas the higher priority. Component scrap increases the dependent requirementsquantity of the component. If a scrap quantity is planned for a higher-levelassembly, assembly scrap and component scrap are both added to the componentlevel.

Component scrap relates only to the individual components in an assembly.During BOM explosion, the system increases only the component quantity bythe calculated scrap quantity.

Operation ScrapBefore high-value components are built into an assembly, your manufacturingprocess may require a quality control check of the assembly. Faulty materialsthat were taken into account in assembly scrap are not passed on to the nextoperation; they are removed from the manufacturing process. Therefore, for ahigh-value component, you plan using operation scrap instead of general assemblyscrap. This scrap quantity refers to the quantity of one component that is to beprocessed in an operation, meaning that the planning run is more exact and youcan determine service and quantity consumption more precisely.

If the component is contained in an assembly for which an assembly scrap quantityhas been maintained, the system only takes the operation scrap into account. Thenet indicator instructs the system to calculate the component operation scrapwithout taking assembly scrap into account (net usage scrap). You should also setthe net indicator if operation scrap has not been maintained and assembly scraphas been entered. The assembly scrap should not, however, be taken into account.

Operation scrap in the BOM relates to the quantity of a component to be processedin an assembly. The specification replaces the estimated assembly scrap for thehigh quality materials and allows for more precise MRP. The net indicator controlsthe operation scrap for components and is calculated without taking into accountthe assembly scrap (net input quantity). You still have to set this indicator if nooperation scrap has been maintained and the assembly scrap is not to be takeninto account.

Operation scrap in the operation results in a fall in quantity in the next operation,and is taken into consideration in scheduling and costing. The scrap percentagemaintained in the operations is added to the material master with the schedulingupdate.


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Scrap Example

Figure 166: Scrap Example

Assembly scrap in the material master can be calculated from operation scrapentered in the routing. The following example shows how the assembly scrap iscalculated. Formula: total scrap quantity (9.75) divided by total yield quantity(90.25) equals 10.80%. Even though the unit of measure is pc, there is no roundingin the scrap calculation.

Operation Scrap Start Qty Scrap Qty Op Yield10 5% 100 5 9520 5% 95 4.75 90.25

Based on the component scrap and operation scrap values defined on the BOM androuting, the system calculates the following planned component and productionquantities:

Material ReqOp

AsmblyScrap

CompScrap

BOMScrap

OpNetInd

ReqQty

Blank 10 12% 2% 0% N 115Gasket 30 12% 3% 0% Y 103Screws 30 12% 7% 0% Y 107

Execution time is also adjusted for the scrap quantities.


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Operation Production Qty Time Target Required Time10 112 10 H 11.2 H20 106 10 H 10.6 H30 101 5 H 20.2 H


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Exercise 27: Scrap in Production

Exercise ObjectivesAfter completing this exercise, you will be able to:� Maintain scrap in the material master, BOM, and routing� Maintain and use assembly scrap, component scrap, and operation scrap� Use the operation net indicator in planning scrap� Use operation scrap in the routing to update assembly scrap in the material

master

Business ExampleYour production for the pump casing creates scrap in several different areas. Youneed to use assembly scrap, component scrap, and operation scrap to accuratelyplan the required quantities. You also want to use the operations scrap in therouting to update the assembly scrap in the material master without planningscrap for both.

Task 1:Maintain assembly scrap, component scrap, and operation scrap in your pumpproduction.

1. Change the material master of your pump R-B1## to plan for 12% assemblyscrap.

2. Change the material masters of your pump components R-T1##, R-T2##,and R-T3## to plan for 2%, 3%, and 7% component scrap, respectively.

3. Change the BOM of your pump R-B1## so planning does not plan for bothoperation and assembly scrap by setting the operation net indicator forR-T2## and R-T3##.

4. Change your routing for the production of material R-B1## in plant 1000 toreflect the operation scrap of 5% that occurs at operations 10 and 20. Also,adjust the standard values of the first three operations to match the data inthe table below.


Activity Op 10 Op 20 Op 30Base Quantity 10 PC 10 PC 5 PCSetup 10 Min 3 Min 0 Min



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Machine 60 Min 60 Min 60 MinLabor 60 Min 60 Min 60 MinScrap in % 5 5 0

Task 2:Test the scrap calculation by scheduling a production order for material.

1. Schedule a production order for 100 pieces of R-B1## due in two months.

2. Analyze the component quantities and operation times to be sure the systemplanned properly for scrap.

Task 3:Update the material master record with the operation scrap from the routing.

1. Update the material master record of R-B1## with the operation scrap fromthe routing.


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Solution 27: Scrap in ProductionTask 1:Maintain assembly scrap, component scrap, and operation scrap in your pumpproduction.

1. Change the material master of your pump R-B1## to plan for 12% assemblyscrap.


b) Enter R-B1## for the material number, choose the MRP1 and MRP3views, and enter plant 1000.

c) In the section for Lot Size Data, enter 12 in the Assembly scrap (%)field. On the MRP3 view be sure the Strategy Group is set to 40and save.

2. Change the material masters of your pump components R-T1##, R-T2##,and R-T3## to plan for 2%, 3%, and 7% component scrap, respectively.


b) Enter R-T1## for the material number, choose the MRP4 view, andenter plant 1000.

c) In the section for BOM explosion/dependent requirements data, enter 2in the Component scrap (%) field and save.

d) Repeat steps b through c for each of the other materials, R-T2## andR-T3##, and enter the correct scrap quantity for each.



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3. Change the BOM of your pump R-B1## so planning does not plan for bothoperation and assembly scrap by setting the operation net indicator forR-T2## and R-T3##.

a) Choose Logistics→ Production→ Master Data→ Bills of Material→ Bill of Material→ Material BOM→ Change or use transactioncode CS02.

b) Enter material R-B1##, plant 1000, BOM usage 1, and choose Enter.

c) In the General Item Overview, select components R-T2## and R-T3##.

d) Go to the Item details screen by choosing the Item icon .

e) In the Item details screen, select the Net ID for R-T2##.

f) Choose Next to move to the details of R-T3##.

g) Select the Net ID and save your BOM.

4. Change your routing for the production of material R-B1## in plant 1000 toreflect the operation scrap of 5% that occurs at operations 10 and 20. Also,adjust the standard values of the first three operations to match the data inthe table below.


Activity Op 10 Op 20 Op 30Base Quantity 10 PC 10 PC 5 PCSetup 10 Min 3 Min 0 MinMachine 60 Min 60 Min 60 MinLabor 60 Min 60 Min 60 MinScrap in % 5 5 0


b) Enter the material R-B1## and plant 1000 and choose Enter .

c) Select operations 10, 20, and 30 and choose Details→ Operationfrom the menu. Enter the base quantity and the standard operationprocessing times from the table. Scroll down to enter the scrap valuesand choose to navigate to the next operation detail screen. Continueuntil all times and scrap quantities have been entered and then chooseto return to the operation overview. Be sure you save your routing.



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Task 2:Test the scrap calculation by scheduling a production order for material.

1. Schedule a production order for 100 pieces of R-B1## due in two months.

a) Choose Logistics→ Production→ Production Control→ Order→Create→ With Material or use transaction code CO01.

b) Enter material R-B1##, production plant 1000, and order type PP01and choose Enter.

c) Enter Total Qty of 100, a Basic Finish date 2 months fromtoday and hit ENTER.

d) Stay in the production order without saving.

2. Analyze the component quantities and operation times to be sure the systemplanned properly for scrap.

a) In the production order, choose Component overview .

b) You should see in the component overview that the system has plannedthe following:

Component Reqmts qtyR-T1## 115R-T2## 103R-T3## 856

c) Choose Operations overview .

d) Select operations 10, 20, and 30 and select the Op. details icon inthe lower left of the screen.

e) Select the Qty/activities tab and compare the data to the table below.

Operation Operation Qty To confirm time10 112 11.2 H20 106 10.6 H30 101 20.2 H

f) When you are finished and are satisfied the production order wasscheduled correctly, exit without saving by choosing and answeringNo to the dialog box.



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Task 3:Update the material master record with the operation scrap from the routing.

1. Update the material master record of R-B1## with the operation scrap fromthe routing.


b) Enter material R-B1##, plant 1000, and choose Enter .




f) In the Scheduling Overview, select the Scheduling Results icon .

g) In the dialog box that appears, you can compare the scheduling resultswith the current material master settings. Choose Update mat. master

in the dialog box.

h) You should receive a message box that says, �Scheduling data markedfor material master update.� Choose OK and back out of the routing.

i) Choose Logistics→ Production→ Master Data→ Routings→ Extras→ Material Master→ Update Material Master or use transactioncode CA96.

j) Enter plant 1000, production planner 0##, and choose Enter .

k) Select your material from the list and be sure to select the Updatewith assembly scrap indicator. Now choose Update mat. master

on the tool bar and check your material masterrecord to be sure it updated correctly.


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Lesson Summary

You should now be able to:� Explain how the assembly and component scrap in the material master field

affect the production process� Explain how the component scrap and operation scrap percentage in the bill

of material affect the production process� Explain how the scrap in the percentage field in the routing affects the

production confirmation process


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Lesson: Production Resources/Tools

Lesson OverviewThis lesson explains how to create and use production resources/tools.


� Describe and use production resources/tools in the routing

Business ExampleAs a production scheduler, several of your products require extensive testing. Thetesting process requires expensive and sophisticated equipment. For the purposeof informing the quality department of its need and duration of use, you think itmight be useful to model in on the production floor. In order to do this you willuse production resources/tools in the routing

Production Resources/ToolsProduction resources/tools are required for production but are not consumed.A PRT may be needed in order to carry out an operation and therefore must beassigned to that operation.

The PRT must be identified by a material master, equipment master, or a PRTmaster.

The input screen for production resources/tools with a material master isautomatically displayed when assigning a PRT to an operation. The PRT categorycan be changed.

Figure 167: Production Resources/Tools


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PLM114 Lesson: Production Resources/Tools

The ECC System differentiates between the following types of productionresources/tools, according to their properties and business function:

� Materials that are accounted for in materials management, for instance ininventory management, requirements planning and procurement.

� Equipment, for instance measuring instruments or valuable tool, which areserviced

� Documents, for instance drawings or programs, which use the documentmanagement system.

� Miscellaneous production resources/tools (with a PRT master record), thatrequire less maintenance in the system.

Production resources/tools can be assigned to operations, activities or phasesin task lists (including standard networks and recipes), production orders andmaintenance orders as well as networks. Production resources/tools that are usedfor testing during production, can be assigned to the corresponding inspectioncharacteristic in the inspection plan.

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

Figure 168: PRT Categories


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Exercise 28: Creating and Assigning PRTs

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create a PRT� Assign a PRT to an operation on a routing

Business ExampleIn your production process, you have production inspection tools that are neededfor testing pumps. You need to create these as PRTs and assign them to yourinspection operations on the routing.

Task 1:Create a PRT to represent your inspection gauge.

1. Create a miscellaneous PRT called INSP-## to represent your inspectiongauge. Be sure you release it for use in production, allow it to be used onlyfor routings, and the unit of measure is pieces.

Task 2:Assign a PRT to your inspection operation of your reference operation set.

1. Assign a PRT inspection gauge to operation 10 of your reference operationset.

2. Display your routing for T-F## and plant 1000 to ensure the PRT is visiblethere also.


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Solution 28: Creating and Assigning PRTsTask 1:Create a PRT to represent your inspection gauge.

1. Create a miscellaneous PRT called INSP-## to represent your inspectiongauge. Be sure you release it for use in production, allow it to be used onlyfor routings, and the unit of measure is pieces.

a) Choose Logistics→ Production→ Master Data→ ProductionResources and Tools→ Production Resources/Tools→ PRT Master(Misc.) → Create or use transaction code CF01.

b) Enter INSP-## and press ENTER.

c) Enter Inspection Gauge ## as the description, Status 03, TaskList Usage 001, and Base Unit of Measure PC.

d) Choose the Default icon to go to the default view.

e) Enter Control Key 1 for all business processes, Ref. start date as04 Start Date for execution, and Ref. date for finish as05 Start date for wait.

f) Save your PRT.



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Task 2:Assign a PRT to your inspection operation of your reference operation set.

1. Assign a PRT inspection gauge to operation 10 of your reference operationset.

a) Choose Logistics→ Production→ Master Data→ Routings→Routings→ Reference Operation Sets→ Change or use transactioncode CA12.

b) Enter the group number of your reference operation set or search for itas previously indicated and choose Enter .

c) Acknowledge the warning message that appears. This message meansthat upon saving, any changes made to the reference operation set willupdate all routings to which it is assigned.

d) Select operation 10 and choose Prod.resources/tools .

e) The dialog box that appears defaults to material PRT. If you want toassign a different PRT, you must choose the appropriate button at thebottom of the box. Choose Others to assign a miscellaneous PRT.

f) Enter INSP-## as the name of the Prod.resource/tool and pressENTER. Respond to any messages that appear.

g) Save the reference operation set.

2. Display your routing for T-F## and plant 1000 to ensure the PRT is visiblethere also.



c) In the operations overview, be sure the PRT column is selected forboth operations 25 and 35.

d) Select one of those operations and choose Prod.resources/tools

.

e) The PRT INSP-## should be visible.


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Lesson Summary

You should now be able to:� Describe and use production resources/tools in the routing


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PLM114 Unit Summary

Unit SummaryYou should now be able to:� Use parallel sequences in modeling complex manufacturing processes� Use alternative sequences in modeling flexible manufacturing processes� Model alternative manufacturing processes using alternative routings� Use production versions to model a very specific production process� Utilize reference operation sets to minimize routing maintenance� Create a reference operation set� Use a reference operation set in a routing� Use a reference operation set as a template to create a routing� Describe in detail the concept of lead time scheduling and updating in-house


schedule� Update the material master record of a material from the routing� Demonstrate the use of interoperation times in the routing for job shop

related environments� Demonstrate the use of Overlapping for a continuous manufacturing process� Demonstrate the use of splitting for multi-capacity work centers.� Describe the use of trigger points to streamline and automate several

administrative processes� Explain how the assembly and component scrap in the material master field

affect the production process� Explain how the component scrap and operation scrap percentage in the bill

of material affect the production process� Explain how the scrap in the percentage field in the routing affects the

production confirmation process� Describe and use production resources/tools in the routing


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Unit Summary PLM114


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Test Your Knowledge

1. Float time that can be modeled in the scheduling of the routing include:Choose the correct answer(s).□ A Float before production□ B Float after production□ C Setup time□ D Queue time□ E Teardown time

2. The duration of an operation consists of a maximum of 5 components.Determine whether this statement is true or false.□ True□ False

3. Teardown and wait time are always scheduled simultaneously.Determine whether this statement is true or false.□ True□ False

4. Only the minimum wait time is scheduled.Determine whether this statement is true or false.□ True□ False

5. Move time is defined only in the operation details.Determine whether this statement is true or false.□ True□ False

6. You can only split an operation processing time on a work center with morethan 1 individual capacity.Determine whether this statement is true or false.□ True□ False


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7. Operation can be set to overlap so that the next operation starts before theprevious operation has finished.Determine whether this statement is true or false.□ True□ False

8. Reduction measures are applied when the lead time schedule of a routingdoes not fit within the basic date schedule.Determine whether this statement is true or false.□ True□ False

9. Which of the following are types of PRT's?Choose the correct answer(s).□ A Material□ B Equipment□ C Component□ D Miscellaneous□ E Document

10. PRT is another name for a component that is used in production.Determine whether this statement is true or false.□ True□ False

11. The same PRT can be assigned to more than one operation on the samerouting.Determine whether this statement is true or false.□ True□ False


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Answers

1. Float time that can be modeled in the scheduling of the routing include:

Answer: A, B, D

Float time that can be modeled in the scheduling of the routing include thefloat before and after production and queue time sometimes referred to asoperation float time.

2. The duration of an operation consists of a maximum of 5 components.

Answer: True

The duration of an operation consists of a maximum of 5 components whichare queue time, setup time, processing time, teardown time, and wait time.

3. Teardown and wait time are always scheduled simultaneously.

Answer: False

Teardown and wait time are scheduled consecutively unless theteardown/wait simul. indicator is set in the operation details of the routing.

4. Only the minimum wait time is scheduled.

Answer: True

Only the minimum wait time is scheduled, the maximum wait time is usedfor information purposes only.

5. Move time is defined only in the operation details.

Answer: False

Move time can be defined in the operation details or by location groups inthe work center.

6. You can only split an operation processing time on a work center with morethan 1 individual capacity.

Answer: True

An operation is split if it is carried out on several machines or by severalpersons at the same time.


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7. Operation can be set to overlap so that the next operation starts before theprevious operation has finished.

Answer: True

To reduce lead time of a routing or production order you can overlapoperations. This means that an operation starts before the previous operationhas finished.

8. Reduction measures are applied when the lead time schedule of a routingdoes not fit within the basic date schedule.

Answer: True

Reduction measures are applied when the lead time schedule of a routingdoes not fit within the basic date schedule

9. Which of the following are types of PRT's?

Answer: A, B, D, E

The 4 types of PRT's are material, equipment, document, and miscellaneous.

10. PRT is another name for a component that is used in production.

Answer: False

PRT's like components are needed for production but they are not consumedlike components which makes them much different than components.

11. The same PRT can be assigned to more than one operation on the samerouting.

Answer: True

Unlike components, PRT's are not consumed in the production process andthe same PRT can be assigned to multiple operations on the same routing.


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Unit 9Engineering Workbench

Unit OverviewThis unit introduces the engineering workbench transaction to create and maintainvarious production planning and execution master data. This transaction canreplace the create and change functions for the bill of material and routing. Thistransaction is typically used to develop and manage complex bills of materialand routings.


� Use the engineering workbench for routing maintenance� Use the EWB browser functions� Navigate in the engineering workbench� Create a work area� Explain the effect of the work area focus� Explain the effect of objects contained in the work area

Unit ContentsLesson: Structure of the Engineering Workbench ... . . . . . . . . . . . . . . . . . . . . . . .494Lesson: Navigating in the Engineering Workbench ... . . . . . . . . . . . . . . . . . . . .500

Exercise 29: Navigating in the EWB ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .505Exercise 30: Navigating in the EWB II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .509

Lesson: Engineering Workbench Work Areas .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .516Exercise 31: Create a Work Area ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525


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Unit 9: Engineering Workbench PLM114

Lesson: Structure of the Engineering Workbench

Lesson OverviewIn this lesson you will learn the benefits of using the engineering workbench. Youwill learn to navigate in the tool, create your own work area, and copy multi-level.


� Use the engineering workbench for routing maintenance� Use the EWB browser functions

Business ExampleYou would like to find the optimum maintenance environment for permanentchanges to allow multiple users to make changes simultaneously. You would alsolike to create new master data and link it in a hierarchy.

Introduction to the Engineering WorkbenchThe engineering workbench (EWB) is part of the PP module in SAP R/3, and is acomplex tool for the integrated processing of BOMs and routings. This meansthat both object types and their links are maintained simultaneously and in detail,with the same user interface.

Figure 169: Benefits of the Engineering Workbench


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PLM114 Lesson: Structure of the Engineering Workbench

The concept of the engineering workbench however, goes far beyond theconventional maintenance of BOMs and routings in that all transactions for theconventional maintenance of these objects are brought together and an extensivechange management is offered. Using complex selection criteria, any numberof objects can be combined; the resulting data then contains no additionalinformation, helping you to achieve a quick overview. The integration of an objectbrowser, as well as various viewers and the digital mock-up viewer, makes theworkbench a central object within PLM.

Figure 170: Formatting of Specific Information

Often times changes to master data happen in complex processes and groups.These activities can arise from new development, design changes, or changesin procedure. Design changes can be changes that are required due to newproducts, rules, warranty dates, and so on. Technical changes can occur in BOMs,routings, or new steps in the process (work center). These types of changes callfor simultaneous changes to the assembly in the BOMs and to the sequence inthe routings.


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Figure 171: Worklist: Purpose

The engineering workbench is a maintenance environment for product structuresand PP objects. Its capabilities far exceed those of the conventional maintenanceof BOMs and routings because you do not have to process routings and BOMsseparately.

The most important objects of the engineering workbench are BOM itemsand operations. Views are applied to these objects, which then further enablethe conventional BOM or routing structures to be used. The full scope of theprocessing functions, Create, Change, and Delete, is supported in all these views.The worklist contains the selected objects so that they can be displayed, changed,or newly created in the engineering workbench. These objects are copied by thesystem from the database into the worklist. Only when the worklist has beensaved, following the processing of objects, are new objects created in the databaseor existing ones changed or deleted.


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Figure 172: Simultaneously Processing Objects in EWB

Different users can work on the same BOM and /or routing simultaneouslywithout locking each other out. Any number of operations from any number ofroutings can be processed at the same time by different people. The same appliesto different BOM items or different operations. If you want to process an objectthat is already being processed by someone else, the engineering workbenchinformation will show you who to contact, so that you can consult with the otherprocessor. The processor can then release the object to you, without interruptingyour work on other objects.

Structure of the Engineering WorkbenchTo display or process an individual object using the EWB, you have to select thecorresponding object. Examples of objects are:

� The task list header of a routing� The operation and sub-operation� The production resource/tool, trigger point, and inspection characteristic� The BOM header� The item and sub-item in the BOM


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Figure 173: Structure of the Engineering Workbench

An object can also take the form of an assignment between individualobjects. Examples of assignment objects are a material-routing assignment, amaterial-BOM assignment, or a component assignment.


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Lesson Summary

You should now be able to:� Use the engineering workbench for routing maintenance� Use the EWB browser functions


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Lesson: Navigating in the Engineering Workbench

Lesson OverviewIn this lesson you will learn the benefits of using the engineering workbench. Youwill learn to navigate in the tool, create your own work area, and copy multilevel.


� Navigate in the engineering workbench

Business ExampleYou would like to find the optimum maintenance environment for permanentchanges. You would like to make changes simultaneously. You would also liketo create new master data and link it in a hierarchy.

Data Selection in EWBWork areas are created in Customizing for the engineering workbench. Usingthe Display work area button, you can specify a standard work area or selectanother work area. In the Select work area dialog box, you also have the optionof branching to the detail screen in the working area. In this detail screen, youcan read the information about the predefined focus and about the object typescontained in the working area.

Figure 174: Choosing the Work Area


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PLM114 Lesson: Navigating in the Engineering Workbench

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

Figure 175: Selection Criteria

You can also use the selection range to restrict the time period for the data. Onlydata that lies entirely or partially in the validity period is copied into the worklist.By using the arrow key on the tab page, you can enter into fields additionalselection criteria that is not contained as selection criteria in the tab pages onthe screen. In addition, you can also use this procedure when you want to selectaccording to several individual values, value intervals, or generically.

Figure 176: Effectivity Window


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With the help of the effectivity window, the display of objects is filtered into theoverview screen. In this figure above, the example is of a working area withfour operations. The operations have been partially changed. If you choosethe selection period in the effectivity window, all operations that are effectivein the selection period are displayed. If you restrict the effectivity window, theoperations that lie completely outside of the effectivity window are not displayed.If you choose the key date in the effectivity window, only those operations that areeffective on the key date are displayed.

Navigation in the Engineering WorkbenchThe screen layout is divided into three elements:

� Toolbar� Cockpit� Overview screen

Figure 177: Navigation in the EWB

The toolbar provides the user with currently available functions at the touch of abutton. The cockpit is always available and controls the engineering workbench.It consists of three areas:

� Process using, for the entry of the key dates or of the change number, toprocess the objects in the worklist. The entry of a key date or a changenumber is necessary when an object has to be created, changed, or deleted.

� Effectivity window, to display a particular time segment of the worklist.� Context, to display the hierarchical relationship of objects in the overview

screen.


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In this figure below there is an input line for each material, BOM, and item. Theoverview screen lists objects that are contained in the worklist and that match theentries in the effectivity window and in the context. It provides information aboutthe object and change status of a particular object type.

Figure 178: Functional Overview of the EWB

In the browser:

� If you double-click on an object, the context block is filled in the EWBwindow and the tab page belonging to it is displayed.

� The right mouse button provides the functions from the graphics displayedabove in a context menu.

Multilevel copy prerequisites:

The copy range has to include the object to be copied. The copy range ispredefined with the settings from the working area and also those from therestrictions. No objects an be expanded unless they are contained in the workingarea. Should the situation arise, check under Extras→ Options→ Copy range.


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Exercise 29: Navigating in the EWB

Exercise ObjectivesAfter completing this exercise, you will be able to:� Navigate in the engineering workbench� Select objects for your work list� Assign materials to routings using the EWB� Change BOMs and routing using EWB� Use EWB locking logic

Business ExampleYou are responsible for maintaining master data for BOMs and routings in yourcompany. To do this you want to use the common maintenance interface in theengineering workbench.

Task 1:Select the routings that you created.

1. Using the P_ALLES working area, select all routings that you created.

2. How many routings did you create?

3. Check whether the groups displayed belong to your products.

Task 2:Using the EWB, create a material-routing assignment.

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

2. In the BOM for pump P-100, change the quantity of the component 100-130to the number of your group. Who currently has the data locked?

3. Can you change another BOM item in the same BOM without the lockbeing lifted?

4. Save the changes and exit the EWB.


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Solution 29: Navigating in the EWBTask 1:Select the routings that you created.

1. Using the P_ALLES working area, select all routings that you created.

a) Choose Logistics→ Production→ Master Data→ EngineeringWorkbench or use transaction code CEWB.

b) Select the P_ALLES working area and choose Continue.

c) Select the Additional Selection Criteria icon .

d) On the Header tab page, choose More Selection Criteria under thetask list section.

e) In the Explorer window that appears, expand the Task list - Headerfolder by clicking the triangle to the left of it.

f) Select Created by and choose Adopt Field Selection .

g) Complete the field with your user ID and chosoe Save.

h) Choose Load Task Lists and BOMs .

i) In the Headers Overview you now see a list of task lists that you created.

2. How many routings did you create?

a) Four routings and one reference operation set.

3. Check whether the groups displayed belong to your products.

a) From the menu, choose Task Lists→ Material-Task list assignments.

b) The Material - Routing Assignments Overview screen now showswhich materials are assigned to your routings.



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Task 2:Using the EWB, create a material-routing assignment.

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

a) Select the routing for T-F## from the list by clicking the button tothe left of it in the table.

b) Choose Copy .

c) In the dialog box that appears, enter material P-100, plant 1000 inthe context section and choose Copy.

d) When you refresh the screen, the new assignment will appear on the list.

2. In the BOM for pump P-100, change the quantity of the component 100-130to the number of your group. Who currently has the data locked?

a) Select the routing-material assignment for P-100 on theMaterial-routing assignments Overview screen and choose Bills ofMaterial→ Items from the menu.

b) Select the line with 100-130 and choose Change.

c) A dialog box appears with the information of which group has thedata locked.

3. Can you change another BOM item in the same BOM without the lockbeing lifted?

a) Yes

4. Save the changes and exit the EWB.

a)


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Exercise 30: Navigating in the EWB II

Exercise ObjectivesAfter completing this exercise, you will be able to:� Reassign component assignments� Use the browser to copy and an operation� Create a routing and a BOM by using multi-level copy

Business ExampleYou are responsible for maintaining master data for BOMs and routings in yourcompany; to do this you use the common maintenance interface in the EngineeringWorkbench.

Task 1:Copy an operation for a similar pump.

1. Copy operation 50 with its corresponding components from the routing formaterial R-F1## to operation 45 in the T-F## routing.

2. In the operation overview, check the copied operation. Select Save to exitediting in the EWB.

Task 2:Your company is introducing a new pump T-H## which is similar to T-F## with 2flywheels. You must create the master data needed to manufacture this new pump.

1. First create the material master record for your new pump T-H## by usingT-F## as the template and create your default views. Change the descriptionto Rotary Pump W/2 flywheels GR##.

2. Now create the rest of the master data using the Engineering Workbench.

The routing should be copied multi-level from the pump with materialnumber T-F## and group counter 1.

Before copying, set the indicator for Set target context after copying onthe Misc. tab page.

Task 3:Display the PRT assignments in the Engineering Workbench.

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



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2. Search for the production resource/tool INSP-## in your routings by usingthe browser. Navigate to the details screen.

3. You have assigned the hollow shaft to operation 40 in your routing formaterial T-F##. Reassign this assignment to operation 45 by using thebrowser.


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Solution 30: Navigating in the EWB IITask 1:Copy an operation for a similar pump.

1. Copy operation 50 with its corresponding components from the routing formaterial R-F1## to operation 45 in the T-F## routing.

a) Use the menu path Logistics→ Production→ Master Data→Engineering Workbench or transaction code CEWB.

b) Select the P_ALLES working area and click continue.

c) Select the Additional Selection Criteria icon .

d) Click Multiple Selection Icon to the right of material and enter R-F1##and T-F## as material numbers.

e) Click the Load Task Lists and BOMs Icon .

f) Confirm the dialog box EWB: Process Using with the specified keydate.

g) Click the Activate Browser Icon to activate the browser, enterapplication PP01.

h) Expand the routing for R-F1## to the operations by clicking thetriangle to the left of R-F1##. Use the same method to navigate tothe operations for material T-F##.

i) Select operation 40 for material R-F1##, right-click and chooseMulti-level Copy from the context menu.

j) Select the standard sequence of the routing for T-F## as the targetobject. Right-click, choose Paste, and enter operation 45.

k) The operation and component assignment now appear in the T-F##routing.

2. In the operation overview, check the copied operation. Select Save to exitediting in the EWB.

a) Right-click the standard sequence in the routing for material T-F## andselect Operations to go to the operations overview.



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Task 2:Your company is introducing a new pump T-H## which is similar to T-F## with 2flywheels. You must create the master data needed to manufacture this new pump.

1. First create the material master record for your new pump T-H## by usingT-F## as the template and create your default views. Change the descriptionto Rotary Pump W/2 flywheels GR##.


b) Enter the material number T-H## and material type for Finishedgoods. Enter T-F## as the copy from material.

c) In the Basic Data 1 view, change the description to Rotary PumpW/2 flywheels GR##.

d) Choose Save .

2. Now create the rest of the master data using the Engineering Workbench.

The routing should be copied multi-level from the pump with materialnumber T-F## and group counter 1.



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Before copying, set the indicator for Set target context after copying onthe Misc. tab page.



c) Select the Basic Selection Criteria icon .

d) Enter T-F## as the material number and 1000 as the Plant number.

e) Click the Load Task Lists and BOMs Icon

.

f) First select the Options Icon , choose the Misc. tab and in the Navigatewhile copying section select Set target context after copying and clickExecute.

g) Select the T-F## routing you wish to copy and click the Copy ObjectIcon .

h) In the Target Data dialog box, enter material number T-H##, plant1000, task list type N Routing and delete the routing group number.

i) Select the Multi-level Copy indicator.

j) Click the Copy Range Icon button to set the indicatorsfor the relevant copy objects (select all) in the EWB: Options dialogbox.

k) If you didn't set it in step b) then in the EWB: Options dialog box, setthe Set target context after copying indicator on the Misc. tab page.

l) Now copy the routing by clicking the copy button.

m) Change the lot-size validity in the table to 1-100,000 and scroll to theright to be sure planner 0## is assigned.

n) Save your data.

o) Be sure to check the Component Assignments, the BOM Header, andBOM Items.



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Task 3:Display the PRT assignments in the Engineering Workbench.

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



c) Enter T-F1## as material number.

d) Click the Load Task Lists and BOMs Icon

.

e) Right-click the line in the browser for the reference operation set formaterial T-F1## and choose Production Resources and Tools.

2. Search for the production resource/tool INSP-## in your routings by usingthe browser. Navigate to the details screen.

a) Select Find .

b) In the Find dialog box, select the object type PRT and enter INSP-##.

c) Double-click the search result to select the production resource/tool inthe upper browser screen. Double-click again in the upper screen toget to the production resource/tools details.

3. You have assigned the hollow shaft to operation 40 in your routing formaterial T-F##. Reassign this assignment to operation 45 by using thebrowser.

a) Drill down in the browser structure and reassign the hollow shaft tooperation 45 by clicking and dragging.

b) Close the browser and exit the EWB without saving.


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Lesson Summary

You should now be able to:� Navigate in the engineering workbench


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Lesson: Engineering Workbench Work Areas

Lesson OverviewIn this lesson we will investigate the work area and how it affects work in theengineering workbench.


� Create a work area� Explain the effect of the work area focus� Explain the effect of objects contained in the work area

Business ExampleUsers will need specific work areas to allow them to do their jobs efficiently.You need to understand how to configure work areas to make them efficient forusers in your company.

Work AreasWork areas are created in Customizing for the engineering workbench. Usingthe Display work area button, you can specify a standard work area or selectanother work area.

Figure 179: Work Area Selection


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PLM114 Lesson: Engineering Workbench Work Areas

In the Select work area dialog box, you also have the option of branching to thedetail screen in the working area. In this detail screen you can read the informationabout the predefined focus and about the object types contained in the workingarea.

Figure 180: Objects in the Worklist

A focus object is an object of the focus object type that meets the selection criteriathat you enter. An environment object is an object whose object type is containedin the working environment and that is assigned to a focus object. Environmentobjects are automatically selected by the system and represent the environmentof the focus object that you are interested in. Using the selection criteria thatyou enter, you immediately determine which focus objects are contained in yourworklist. The focus objects form the core of your worklist.

An example would be loading operations in the worklist by selecting according tothe work center:

� If the focus is set on the operation, then only those operations that use thiswork center are read into the worklist.

� If the focus is set on the routing header, then the operations that are containedin the routings are also read into the worklist.


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Figure 181: Example: Focus BOM Header

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

1. All BOM headers, with their items and subitems, are copied into the worklistthat contains these components.

2. All task list headers belonging to the BOM headers of these componentsare copied in to the worklist.

3. Additionally, the objects that are connected to the task list header and whoseobject type is included in the working environment are also copied intothe worklist.

4. All component assignments between the items in the BOM headers, and theoperations for the corresponding routings, are copied into the worklist.


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Figure 182: Example: Focus BOM Item

The focus lies on the object type item. With the focus on the item, the followingobject types should also be included in the working environment: BOM headerand subitem, routing header with sequence, operation, PRT, trigger point, andinspection characteristic. A component has been entered as selection criteria.

1. Only the items that correspond to these components, are copied into theworklist with their BOM headers and subitems.

2. All operations to which this component has been assigned are copied into the worklist.

3. Additionally, the objects that are connected to this operation and whoseobject type is contained in the working environment are copied into theworklist, for example, task list header, sequence, and so on.

4. As a further restriction, the material / routing assignment is taken intoaccount.


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Figure 183: Different Focus: BOM

These examples illustrate the expected results of a different focus. The prerequisitefor these results is that the working area always contains the same object types.The working area (with focus) and the selection criteria can be viewed in themenu entry Extras:

� Working area� Selection criteria

Figure 184: Different Work Areas: BOM


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These examples illustrate the expected results of a different working area. Theprerequisite for these results is that the focus is always on the same focus object.The working area (with focus) and the selection criteria can be viewed in themenu entry Extras:

� Working area� Selection criteria

As an example, the focus is defined in reference to the BOM header.

Figure 185: Example: Focus Task List Header


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The focus lies on the object type routing header. In addition to the focus routingheader, the object types sequence, operation, PRT, trigger point, inspectioncharacteristic, BOM header, item, and subitem should all be contained in theworking environment. A work center has been entered as selection criteria.

1. All routing headers are copied with their sequences and operations intothe worklist, provided that one of the operations contains this work center.Additionally, the objects that are connected to the operation, and whoseobject type is included in the working environment, are also copied intothe worklist.

2. All BOM headers that are assigned to these routing headers are copied intothe worklist.

3. All objects that are on a lower level to these BOM headers are copied intothe worklist.

4. All component assignments that are between the operations of the routingheader and the items of the assigned BOM headers are copied into theworklist.

Figure 186: Example: Focus Operation


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The focus lies on the operation object type. In addition to the focus operation,the following object types should all be contained in the working environment:routing header, sequence, PRT, trigger point, inspection characteristic, BOMheader, item, and subitem. A work center has been entered as selection criteria.

1. All objects that are at a higher or lower level than the focus objects coveredby these work center operations are copied into the worklist.

2. All items that are assigned to these operations, including the componentassignments, are copied into the worklist.

3. All objects that are on a higher or lower level than these items are copiedinto the worklist.

4. The assignments between routing headers and BOM headers, determined insteps 1 and 3, are copied into the worklist.

Figure 187: Routing: Different Focus

The figure above illustrates the expected results of the different focus. Prerequisitefor the respective result is that the working area always contains the same objecttypes. The working area (with focus) and the selection criteria can be viewed bychoosing Extras→ Working Area Details→ Selection Criteria Details.


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Figure 188: Routing: Different Work Area

The figure above illustrates the expected results of a different working area. Aprerequisite for the respective results is that both examples use the same focus.The working area (with focus) and the selection criteria can be viewed by choosingExtras→ Working area details→ Selection criteria details.


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Exercise 31: Create a Work Area

Exercise ObjectivesAfter completing this exercise, you will be able to:� Create a work area for use in the engineering workbench

Business ExampleYou need to create different work areas for different users in the engineeringworkbench.

Task 1:Create a work area with focus on the BOM header and use it to make a change ina BOM.

1. Create a work area called PLM## with focus on the BOM header.

2. Use your new work area to make a change to the quantity of component 30of the BOM of T-F##. What is missing in the work area that prevents youfrom making this change?

Task 2:Change your work area to focus on the task list header and include task list header,operations, and material-routing assignments in the work area. Use you work areato assign BOM components to an operation on the routing.

1. Change your work area, PLM##, to focus on the task list header. Include tasklist header, operations, and material-routing assignments in the work area.

2. Use your new work area to assign material components of the BOM ofT-F## to operations. What is missing in the work area to be able to makethis change?


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Solution 31: Create a Work AreaTask 1:Create a work area with focus on the BOM header and use it to make a change ina BOM.

1. Create a work area called PLM## with focus on the BOM header.

a) In the IMG, choose Production → Basic Data → EngineeringWorkbench→ Edit Working Areas or use transaction code OP77.

b) Choose the New entries button.

c) Enter PLM## as the name of your working area with description WorkArea ##.

d) In the Focus section, select BOM Header.

e) In the Contained in Work Area section select BOM Header and chooseSave.

2. Use your new work area to make a change to the quantity of component 30of the BOM of T-F##. What is missing in the work area that prevents youfrom making this change?

a) From the main menu, choose Logistics→ Production→ Master Data→ Engineering Workbench or use transaction code CEWB.

b) Select your new PLM## working area and choose Continue.

c) Enter T-F## as the material number.

d) Choose the Load BOMs icon.

e) Try to drill down to the item level in the BOM. The browser doesn't letyou, and the menu path Bills of Material→ Items is greyed out.

f) It is not possible to drill down to the item level because only headerswere included in the work area.



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Task 2:Change your work area to focus on the task list header and include task list header,operations, and material-routing assignments in the work area. Use you work areato assign BOM components to an operation on the routing.

1. Change your work area, PLM##, to focus on the task list header. Include tasklist header, operations, and material-routing assignments in the work area.

a) In the IMG, choose Production → Basic Data → EngineeringWorkbench→ Edit Working Areas or use transaction code OP77.

b) Select your work area, PLM##, and choose Details .

c) In the Focus section, select Header.

d) In the Contained in Work Area section, select Operations andeverything above it in the list will be automatically selected.

e) Choose Save.

2. Use your new work area to assign material components of the BOM ofT-F## to operations. What is missing in the work area to be able to makethis change?

a) From the main menu, choose Logistics→ Production→ Master Data→ Engineering Workbench or use transaction code CEWB.

b) Select your new PLM## working area and choose Continue.

c) Enter T-F## as the material number.

d) Choose Load Task Lists and BOMs .

e) Select a routing and choose Task Lists→ Component Assignments.Unfortunately, it is greyed out.

f) It is not possible to drill down to the item level because BOM itemswere not included in the work area.


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Lesson Summary

You should now be able to:� Create a work area� Explain the effect of the work area focus� Explain the effect of objects contained in the work area


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PLM114 Unit Summary

Unit SummaryYou should now be able to:� Use the engineering workbench for routing maintenance� Use the EWB browser functions� Navigate in the engineering workbench� Create a work area� Explain the effect of the work area focus� Explain the effect of objects contained in the work area


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Course Summary PLM114

Course SummaryYou should now be able to:

� Maintain material masters and bills of materials� Maintain routings and work centers� Assign material components to operations� Managed updates to various master data objects� Execute reports on various master data objects� Model various manufacturing options in the bill of material and routing� Maintain master data using the engineering work bench


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IndexBbatch management, 76batch master record, 76bill of material, 14BOMalternative determination,193archiving, 160by-product, 347co-product, 345comparison, 180default settings, 190explosion report, 178modification parameters,189recursiveness, 154status, 192where-used list, 179�180

BOM categories, 135BOM status, 137BOM usage, 136BOM validity, 147Cchange materialarchive, 94delete, 92extending, 88mass maintenance, 91material status, 89material type, 89

characteristic, 74class, 74class type, 74classification, 72Client, 8Company code, 9component allocation, 298Continuous flow, 454

DDistribution channel, 12Division, 12Eengineering changemanagement, 315

engineering changemanagement (ECM),156

Ffield selection, 108Float before/after production,450

GGroup BOMs, 149IIndividual Capacities, 454industry sector, 50

see also influencing factorsitem categoryconfiguration, 195variable size, 193

Llow-level code, 141Mmaterial assignment, 296Material master, 13material number, configuring,50

material status, 89, 106material type, 48, 105Move time, 452MRP area, 32MRP groups, 57MRP profile, 56


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Index PLM114

OOverlapping, 454Pplantdefinition, 23

Plant, 9Processing time, 452PRTs, 480Purchasing group, 10Purchasing organization, 10QQueue time, 451RReduction measures, 455routingcomponent allocation, 298material assignment, 296reporting, 318suboperation, 307user- defined fields, 309variable-size items, 299

routings, 16

SSales Area, 12Sales organization, 11Scheduling margin Key, 450screen sequence, 111Setup time, 452Shipping Point, 12Splitting, 454storage location, 27Storage location, 9subitems, 139suboperation, 307TTear down time, 452Uunit of measure, 52groups, 54

WWait time, 452work center, 15


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FeedbackSAP AG has made every effort in the preparation of this course to ensure theaccuracy and completeness of the materials. If you have any corrections orsuggestions for improvement, please record them in the appropriate place in thecourse evaluation.


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Date post:	03-Dec-2014
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