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Production PlanningProduction PlanningMaster DataMaster Data
EGN 5620 Enterprise Systems Configuration EGN 5620 Enterprise Systems Configuration
Spring, 2015Spring, 2015
Business Module for Business Module for Selling Finished Goods by ProductionSelling Finished Goods by Production
January 2008January 2008
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Pre-Sales Activity
Sales Order
Delivery Billing
Planned Order
Production Order
Completion Confirmation
In Inventory
Plant or Warehouse
Availability Check
NO
YES
Goods Issued to Delivery
Goods from Production Order
General Ledger Accounts
InventoryPostings
AccountsReceivable
Issue Goods to Production
Order
Purchase Requisition
Purchase Order
Goods Receipt
Invoice Receipt
AccountsPayable
NO
Or
Production and PlanningProduction and PlanningMaster DataMaster Data
SAP Implementation SAP Implementation
Business Process Integration Business Process Integration
January 2008January 2008
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MM
PP
SD
Org
Dat
a
Rules
MM
PP
SD
Master D
ata
MM
PP
SD
FI SDMM
FI
FI
FI
PP
Business Process IntegrationBusiness Process Integration
January 2008January 2008
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PP
Org
Dat
a Ma
ste
r Data
PP
Ru
les
PP
PP
PP Organizational DataPP Organizational Data Client
◦ An independent environment in the system Company Code
◦ Smallest org unit for which you can maintain a legal set of books Plant
◦ Operating area or branch within a company Manufacturing, distribution, purchasing or maintenance facility
Storage Location◦ An organizational unit allowing differentiation between the various stocks of a
material in a plant Work Center Locations
◦ An organizational unit that defines where and when an operation is performed◦ Has an available capacity◦ Activities performed are valuated by charge rates, which are determined by
cost centers and activity types. ◦ Can be machine, groups of machines, people, production lines or groups of
craftsmen
GBI Structure for PPGBI Structure for PP
Global Bike
Global Bike Inc. Global Bike Germany GmbH
Dallas Heidelberg
Client
CompanyCode
Plant
StorageLocation
Raw Materials
Semi-fin. Goods
Finished Goods
Miscellaneous
Raw Materials
Semi-fin. Goods
Finished Goods
Miscellaneous
Assembly
Packaging
Inspection
Assembly
Packaging
Inspection
(Work Center Location)
Organization Data Organization Data Plant-specific organizational units
◦MRP controller ◦Production controller◦Production scheduler◦Planner group ◦Person responsible (financially)
Non-plant specific organizational units◦ Capacity planner
January 2008January 2008
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BPI PP master data BPI PP master data
January 2008January 2008
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PP
Ma
ste
r Data
PPPP
PP
Master Data for Production Master Data for Production PlanningPlanning
MaterialBill of Materials (BOM)Work CenterRoutingProduct Group
January 2008January 2008
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Material Data (Review)Material Data (Review)Definition
◦Physical objects to buy, transform into, sell, maintain other resources, or use in support for business activities.
Generic classification(material types) :◦Trading goods◦Raw materials◦Semi-finished products (WIPs)◦Finished products◦Consumables (e.g., stationery, production tools)◦Spare parts (for maintenance)
Bill of MaterialsBill of MaterialsBOM is a hierarchical structure of the materials
needed to produce a finished goods or semi-finished goods.
BOMs in SAP are defined as single-level, but can be constructed multi-level by nesting several single-level BOMs.
Nesting refers to a hierarchy in which a bill of materials contains its own bills of materials.
January 2008January 2008
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Bill of Material Master DataBill of Material Master DataBOM in SAP consists of a header section and an
item section.
Header section includes data that apply to entire BOM, such as finished material number, plant, usage, validity, status, and base quantity.
Usage identifies the purpose for which the BOM can be used. For example, 1 is for production.
The BOM is valid from the date specified in the header.
January 2008January 2008
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Bill of Materials Master DataBill of Materials Master DataItems section identifies all materials needed to make
finished goods or semi-finished goods identified in the header.
Data for each item are: ◦ item category, ◦ material number, ◦ description, &◦ Quantity
Item category◦ Tell how material is used in the BOM.
January 2008January 2008
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BOM MM Item CategoryBOM MM Item Category
L: Stock itemN: Non-stock itemR: Variable –size itemT: Text item used to include notes and
comments within the BOM. Notes may explain how to use the material or identify any unusual assembly requirement.
D: Document item used to include document such as engineering drawings, assembly instructions, and photographs.
January 2008January 2008
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BOM MM Item CategoryBOM MM Item CategoryK: Class item used in variant BOMs to identify a
class or group of items. A variant BOM is used to create multiple versions.
M: Intra material, or phantom items used as a logical grouped set of materials that could collectively be considered as a single material. Phantom material is not an actual material and is mostly temporarily used during production planning.
January 2008January 2008
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Where to use BOM?Where to use BOM?1. MRP uses BOM to determine dependent
requirements
2. Controlling uses BOM to calculate product costs
3. Production uses BOM to issue the proper quantities of components and raw materials to the shop floor
January 2008January 2008
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Bill of Materials – An ExampleBill of Materials – An ExampleBOM for a Bicycle1. Wheel Assembly
1.1 Tire1.2 Tube1.3 Wheel1.4 Hex nut1.5 Lock Washer1.6 Socket Head Bolt
2. Frame3. Derailleur Gear Assembly
4. Seat Kit
5. Handle Bar
6. Pedal Assembly
7. Chain
8. Brake Kit
9. Warranty Document
10. Packaging
Single-Level Single-LevelFinished Bike
Handle Bar
Wheel Assembly
Frame Chain
Derailleur GearAssembly
Warranty Doc.Seat Kit
Brake Kit
Pedal Assembly
Packaging
Bill of Materials: Single-levelBill of Materials: Single-level
Multi-Level
Single Level vs. Multi-Level BOMSingle Level vs. Multi-Level BOM
Single-LevelFinished Bike
Handle Bar ChainDerailleur Doc.Seat BrakePedal Pack.
Single-Level
Wheel Frame
Tire
Tube
Wheel
Hex nut
Lock
BoltMulti-level
◦Several products with a large proportion of identical parts.
Single-Level
Variant Bill of MaterialsVariant Bill of Materials
Deluxe Bike (red)
Handle Bar
Aluminum Wheel
Frame red Chain
Derailleur GearAssembly
Warranty Doc.Seat Kit
Brake Kit
Pedal Assembly
Packaging
Single-Level
Professional Bike (black)
Handle Bar
Carbon Wheel
Frame black Chain
Derailleur GearAssembly
Warranty Doc.Seat Kit
Brake Kit
Pedal Assembly
Packaging
Work CenterWork CenterWork center is a location where value-added
work for producing a finished or semi-finished product is carried out.
A work center can be a machine, a group of machines, an entire production line, a work area, or a person or group of people who are responsible for completing operations.
A work center is a resource that can be used for a variety of purposes and for multiple processes.
January 2008January 2008
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Work Center - CapacitiesWork Center - CapacitiesWork center used to define capacities
◦Labor◦Machine◦Output◦Emissions
Capacities used in◦Capacity requirements planning (CRP)◦Detailed scheduling◦Costing
January 2008January 2008
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Work Center – Where usedWork Center – Where usedWork Center is used:
◦To be assigned as cost center◦To be allocated with Human Resources (HR)
Positions with requirements People with qualifications
January 2008January 2008
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Work Center ViewsWork Center ViewsWork Centers have multiple views of:
◦Basic data◦Default values◦Capacity overview◦Scheduling◦Cost center assignment◦Technical data
January 2008January 2008
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Work Center – Basic data sectionWork Center – Basic data section
January 2008January 2008
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Name, and description of the work centerPerson or group of people who are responsible for
completing operationsTask list: a list of operations that are required to
accomplish a task. Operations are the specific tasks that must be completed, such as drilling, cutting, assembling. In production, a task list takes the form of a product routing or a master recipe.
Standard value key: used to assign standard or planned values for operations, such as setup and execution times. Companies use these values to calculate costs, execution times, and capacity requirements.
Work Center – Basic dataWork Center – Basic data
January 2008January 2008
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Work Center – Default Values Work Center – Default Values
January 2008January 2008
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Default Values: for operations performed at the work center.
Control Keys: specify how an operation or a sub-operation is scheduling, how costs will be calculated, and how operations will confirmed once they are completed in the work center.
Wage data: used by processes in human capital management, such as payroll.
Standard value keys: identify the normal time elements – the activities that consume time associated with the work center. Typical time elements are setup time, machine time, labor time, and teardown time.
Work Center – Default ValuesWork Center – Default Values
January 2008January 2008
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Work Center – Capacities/SchedulingWork Center – Capacities/Scheduling
January 2008January 2008
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Available capacity defines how much work can be performed at the work center. ◦ A work center can include more than one resource or
capacity, such as labor and machine.
Scheduling basis determines the specific capacity to be utilized for production.
Work Center - Capacities/SchedulingWork Center - Capacities/Scheduling
January 2008January 2008
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Work Center - CostingWork Center - Costing
January 2008January 2008
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A work center is associated with a cost center which is a container for accumulation of costs. Costs associated with operations completed in a work center are calculated using formulas that utilize the costs and standard values associated with each activity type, for example,
setup, labor, and machine.
Work Center - CostingWork Center - Costing
January 2008January 2008
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Product RoutingProduct Routing
A list of tasks or operations that must be performed to convert a material to a part, component, or product.
Routing is a sequence of operations which detail the manufacture of a product
Routings are used as a template for production orders and run schedules as well as a basis for product costing.
January 2008January 2008
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RoutingRoutingRouting are used to determine:
OperationsWork centersMaterial components Production resources and toolsQuality Checks
January 2008January 2008
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Routing – an ExampleRouting – an Example
Routing for Finished Bike
Operation
Work Center
Plant
Control Key
Description
Time and Unit of Measure
Activity Type
Routing UseRouting UseRoutings will be used in
◦Scheduling (dates, times)◦Costing◦Capacity planning◦Production orders
January 2008January 2008
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RoutingRouting
January 2008January 2008© SAP AG - University Alliances and The Rushmore Group, LLC © SAP AG - University Alliances and The Rushmore Group, LLC 2007. All rights reserved.2007. All rights reserved. 3838
StandardSequence
AlternateSequence
ParallelSequence
Operation 10
Operation 20
Operation 30
Operation 40
Operation 10
Operation 20
Operation 30
Operation 40
Operation 25
Operation 20
Operation 10
Operation 30
Operation 40
Operation 25
Material Types Allowed in ProductionMaterial Types Allowed in ProductionMultiple material types may be used in a
routing/BOMRaw materialsSemi-finished productTrading goods are allowed but not standardText or Reference materials common
January 2008January 2008
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Controlling Activities for ProductionControlling Activities for Production
Used to perform internal cost allocation, where activities by a cost center are measured◦Labor time◦Machine hours
Output activities are valuedAllocation of an activity type is always
made with the allocation cost element created in activity type planning
January 2008January 2008
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Activity Prices Activity Prices Prices (costs) for planned activities
◦Fixed or Variable Labor = $$/hour Machine = $/hour Overhead = %
January 2008January 2008
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Activity Type/Price PlanningActivity Type/Price Planning
January 2008January 2008
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Product GroupProduct Group
Aggregate planning that group together materials or other product groups (Product Families)◦Manufacturing procedure◦Product design◦Market niche, etc.
Proportional Factors (Percentages for components)
Product GroupsProduct Groups
January 2008January 2008
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• Multi-level or single-level– A product group is multi-level if it contains
other product groups– Lowest level in a product group hierarchy
always consists of materials.– A product group is single-level if its members
are materials only– A material or product group can be a member
of more than one owner product group
Production GroupProduction Group
January 2008January 2008
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PP RulesPP Rules
January 2008January 2008
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PPPP
Ru
les
PP
PP
MRP Control ParametersMRP Control ParametersEnvironment
◦Number rangeMaster Data
◦Materials Requirements Planning controllers◦Float times
Planned Orders◦Conversion order type◦Dependant requirement availability
January 2008January 2008
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MRP Control Parameters MRP Control Parameters
Planning run ◦Bill of Material (BOM) selection ◦External procurement◦Planning horizon
Availability Check◦Material◦Production Resource/Tool (PRT )◦Capacity
Scheduling Control Parameters
January 2008January 2008
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General Planning ParametersGeneral Planning Parameters
Order Type Control Parameters◦Types of routings, ◦BOM’s per order type:
manually or automatically◦Availability checking
Create Confirmation Parameters ◦Reservations◦Status Updates
Define Valuation of Goods Received◦Moving Average Price Control evaluation
January 2008January 2008
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MM Planning ParametersMM Planning Parameters
Materials Requirements Planning views ◦for materials
Work Scheduling views ◦for manufactured products
January 2008January 2008
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GBI, Inc. GBI, Inc.
Production and PlanningMaster Data
GBI. Organizational Structures GBI. Organizational Structures
Plant (DL## Plant (DL## /MI##/SD## _)/MI##/SD## _)
Client (320) Client (320)
Chart of Chart of Accounts (GL##)Accounts (GL##)
CompanyCompanyCode (US##)Code (US##)
Fiscal YearFiscal YearVariant (K1)Variant (K1)
Credit ControlCredit ControlArea (GL##)Area (GL##)
PurchasingPurchasingOrganization Organization
(US##)(US##)
Purchasing Purchasing Group (N##)Group (N##)
Controlling Controlling Area (NA##)Area (NA##)
RM##RM## FG##FG##
Work CenterWork Center
Work center Work center (ASSY/INSP/(ASSY/INSP/PACK/MANT/PACK/MANT/
SERV)SERV)
Shipping Point (DL##/MI##/SD##)Shipping Point (DL##/MI##/SD##)
SF##SF## TG##TG##
MI##MI##
ASSM10##ASSM10## PACK10##PACK10##INSP10##INSP10##
BOM - ExampleBOM - Example
January 2008January 2008
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RoutingRouting
January 2008January 2008
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PPP OrdersPPP Orders
Planned Order (planning)◦A request created in the planning run for a
material in the future (converts to either a production or purchase order)
Production Order (execution)◦A request or instruction internally to produce a
specific product at a specific timePurchase Order (execution)
◦A request or instruction to a vendor for a material or service at a specific time
Exercises: Exercises: (Due Date – 3/30/2015)(Due Date – 3/30/2015)1. Determine work center location2. Create activity type3. Change activity output/prices4. Determine person responsible5. Create capacity6. Create work centers7. Create MRP views for raw materials8. Create semi-finished goods9. Create finished goods10. Create bill of materials11. Create product routings12. Create product groups