lo215 - production orders

8/11/2019 LO215 - Production Orders

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LO215 Production Orders LO215

Release 640 04/06/2006


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LO215 Production Orders

SAP AG

LO215LO215

Production OrdersProduction Orders

System R/3 Release 4.6C October 2000 5004 2355


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Copyright 2004 SAP AG. All rights reserved.No part of this publication may be reproduced or t ransmit ted inany form or for any purpose without the express permission ofSAP AG. The information contained herein may be changedwithout prior notice.

Copyright

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products and services, if any. Nothing herein should be construed as constituting an additional warranty.


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Production Planning

Level 2 Level 3

ManufacturingPlanning &Execution for Discrete & Repetitive

LO050 5 days

EngineeringChangeManagement

LO980 3 days

BatchManagement

LO955 3 days

KANBAN

LO235 2 days

Classification

LO985 3 days

Special Features ofLIS in Production

LO275 2 days

Logistics InfoPlanning

LO935 2 days

CAP Calculation of Standard Values

LO720 2 daysRepetitiveManufacturing

LO225 3 days

Capacity Planning

LO230 5 days

LogisticsInformationSystem (LIS)Reporting

LO930 2 days

Basic DataPart 2

LO206 3 daysBasic Data forDiscreteManufacturing

LO205 3 days

ProductionOrders

LO215 5 days

ProductionPlanning

LO210 5 days

VariantConfiguration Part 1

LO990 5 days

VariantConfiguration Part 2

LO991 3 days


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Requirements

Necessary: Knowledge of Production Planning andControl

LO205 Basic Data for DiscreteManufacturing

LO206 Basic Data Part 2

Recommended: LO050 Manufacturing Planning andExecution for Discrete and Repetitive


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Target Group

Members of the project team who are responsiblefor the implementation of production orders(consultants and administrators)Managers and employees in production areas(production schedulers, controllers, supervisorsand operators)

Duration: 5 days

Information for participants The training materials are not designed to be a self-teach program. They are only complete when used in

conjunction with the explanations of the instructor. You are given space on each page of the trainingmaterials to write down this additional information.


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At the conclusion of th is course, you will beable to:

Course Goal

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Use product ion orders.

Create, release and fully implementproduction orders. You will be able tomake system settings and also understandproduction orders in context.


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Classify production orders in the production planning andexecution environment (demand management, requirementsand materials planning, sales order processing and so on)Implement or apply production orders and their mostimportant functionsUnderstand and use the basic order management functionsin detailUse the information systems for production orders

Take into consideration the integration relationships withinthe production order Teach yourself additional special functions

Course Objective(s)

At the conclusion of this course, you will be able to:

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Unit 8 Order Control

Unit 9 Confirmations

Unit 10 Goods Receipt

Unit 11 Settlement, Archivingand Deletion

Unit 12 Information Systems

Unit 13 Mass Processing and

AutomationUnit 14 Collective Orders

Unit 1 Introduction

Unit 2 Overview

Unit 3 Order Structure /Processing

Unit 4 Order Creation /Order Change

Unit 5 Order Release

Unit 6 Printing Order DocumentsUnit 7 Material Staging

Preface

Appendix

Course Content


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Course Overview Diagram (1)

Goods ReceiptGoods Receipt 1010

ConfirmationsConfirmations 99

Information SystemsInformation Systems

1212

SettlementSettlement ,, Archiv ing Archiv ingandand DeletionDeletion 1111

CollectiveCollective OrdersOrders 1414

Mass ProcessingMass Processingand Automationand Automation 1313

MaterialMaterial StagingStaging 77

111

Order Order StructureStructure //ProcessingProcessing 33

Order Contro lOrder Contro l 88

PrintingPrintingOrder Order DocumentsDocuments 66

Order ReleaseOrder Release

55

Order Order CreationCreation //Order ChangeOrder Change 44

OverviewOverview 22

Introduction


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Overview: Contents

Overview of the process chain for order-related productionThe process chain in other production planning andcontrol scenarios

Characteristics of order-related production

Order-related production in the organization structures ofthe R/3 System

Master data prerequisites for production orders


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At the conclusion of th is un it you will be ableto :

Overview: Topic Objectives

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Recognize the different steps in the process chain fororder-related production

Recognize the most important characteristics of order-related production

Define how production orders are classified in the R/3application component PP and in the organizationstructures


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55


Overview Diagram (2)

IntroductionIntroduction 11

22


OverviewOverview


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Subsystems of the PP Application

PPPP

PPPC

Prod. Costing

PPIS

Prod. InfoSystem

PPMRP

Mat. RqmtsPlanning

PPSOP

Sales & Oper.Planning

PPMPS

DemandMgmt

PPBD

BasicData

PPPPSFCSFC

ShopShop Floor Floor ControlControl

PPPI

ProcessMfg

PPREMRep.Mfg

PPCRP

CapacityPlanning

PPKANKANBAN

The Production Planning (PP) application incorporates a number of integrated working subsystems . Each time you use the R/3 system, you should determine precisely which components are appropriate

to your needs. PP-Shop Floor Control is the subsystem for order-related production .


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Order-Related Production: Characteristics (1)

Order-related productionBased on production orders with order category '10'

Production by order lot sizes (see Lot-Sizing Procedure)

Integrated logistical and controlling functionality

Production by production versions (for example,production lines)

Detailed status management

Full integration into capacity planningPDC - Interface (PP-PDC) for download and upload

Material staging control led by material reservations


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Order-Related Production: Characteristics (2)

Availability checks for material, capacity, production resourcesand tools

Various options for entering actual data (quantity, time)

Order, operation, time event and progress confirmations

Extensive order-related or product-related controlling

Full integration in the Logistics Information System (LIS) andBusiness Information Warehouse (BW)

Archiving and retrieval funct ionNumerous special functions

multi-level collective orders, trigger points, serial numbers, ordersplit, external processing, rework, WIP, variance calculation,cross-plant production, batch creation and batch determination,co-products and so on


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Cross-Application Functions

Material forecast Sales & Distribution

Inventory

E A C D

B

C a p a c

i t y p

l a n n

i n g

C a p a c

i t y p

l a n n

i n g

C o s

t i n g

C o s

t i n g

Demand program Sales reqmtsPlanning

Requirements planning

Production order Production order

Order Order processingprocessing

Goods receiptGoods receipt

Order Order settlementsettlement

Goods issueGoods issue

Purchase requisition

Purch ase order

Goods receipt

Invoice receipt

Planned order Planned o rder

Production order management is a central component of a complex process chain that starts withindependent requirements (planned or customer requirements) and ends in the issue of a finished

product. Production order management in the SAP System only controls the whole process of in-house

production . Production order management uses the following system components :

ALE, Workflow, Customizing, word processing, factory calendar, classification, communication andgraphics.


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Production Planning and Control Data

Confirmations

CO object (cost col lector)

Material movements (goods receipt / issue)

Production orders

Factory calendar

Mat. master

Work centers

Bills of material

Routings

Prod. resources/tools

CAPP formulas

Documents

Master Master datadata

TransactionTransaction datadata

Data that does not change frequently is defined as master data of the Production Planning System. Transaction data are documents that have a restricted time application. In the Production Planning

System these are production orders. Documents for confirmations, costs (CO objects) and material movements are assigned to the production

orders.


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Corporate Order Management

Order

Assign mentto a

material

Order Order Order

Overheadcost

orders

Capitalinvestment

orders

Goods for the market Internal company goods and services

Sales-Related

Goodssold

Goods instock

Company Internal

Cannot b eactivated Can be activated

Customer Warehouse Cost center Asset portfolio

Logi sti c f un ctio ns (qu ant iti es and v alues) Cost ac cou nti ng fun cti ons (v alues)

Assign mentto a

sales order

Corporate order management is divided into two basic forms : Sales-related orders and companyinternal orders .

Within company internal orders, a distinction has to be made between:Orders purely for object control within cost accounting (for example, for promotional purposes orfor use in trade fairs). Productive and value-added orders that can be activated (for example, for in-house production on a production line).

In the R/3 System, both basic order forms are assigned to SAP applications via order category . Examples: Production order (PPS) -> PP Production Planning

Plant maintenance order -> PM Plant Maintenance Network -> PS Project SystemOverhead cost order -> CO Controlling

Capital investment order -> CO Controlling


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Document Type, Order Category, Order Type

Material accounting documentsFinancial accounting documents

Orders

PP process order PS networkCO internal order CO production order CO model order PM plant maintenance order

Produ ction or der (external number range)Production order (special types)

Production order (internal number range)

PP production order

Document typ eDocument typ e

Order categoryOrder category

Order typeOrder ty pe

The document type is used to differentiate between business transactions in the R/3 System. Orders are one category of business transaction. Orders are divided up according to order category , as it is possible to have different orders within the

different applications. The system predefines fixed order categories for each application. You have the option of individually defining order categories for each order type within an application. An order type is used to control different processes:

Number assignmentSetting default valuesUser-specified status managementUser-specific field control (not for production orders in Release 4.7)

Control of special functions (activating BDE, QM, LIS,... .) You define the settings for this in Customizing.


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Definitions in the Production Order

WhatWhat isis being producedbeing produced ??

WhenWhen isis it beingit beingproducedproduced ??

How much hasHow much h as toto bebeproducedproduced ??

For whom are we producingFor whom are we producing ??((costcost object)object)

Which resourcesWhich resources andand methodsmethodsare being usedare being used in thein the productionproduction ??

Which costs are incurred byWhich costs are incurred by th eth eproductionproduction ??

Products Ac ti vi ty

Planned ord er datesBasic order datesCalculated datesConfirmed dates

ReleaseStartFinal

Planned order quantityProduction order quantityConfirmed quantity

MaterialCost center

Order Asset

Material usageProd. resources/toolsChecks

Planned Ac tual

The production order is determined by a series of definitions for manufacturing a product.


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Production Orders and Organizational Structures

Organizational unitsOrganizational units

Production order

Shop floor control

Demand management

Requirements planning

Inventory management

Company

Controlling areas

Sales organizations

Company codes

Valuation areas

PlantsPlants

Storage location s/batches/special stocks

Purchasing organizations

Production orders generally relate to the organizational unit plant . The organizational units above a plant can be structured in various ways.


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Master Data for the Production Order

Required quantity and usage valueControl dataRequired quantity and usage valueControl data

BOM

Routing

MaterialMaterial

BOMBOM

Work center Work center

RoutingRouting

ProdProd .. resourcesresources //toolstools

Material usage (Mat. no., item cat., quantity)Storage location (proposal for withdrawal)

Operation default values Available capacity and formu la requ ir ements Activi ty type and for mula costs

OperationsStandard values

Procurement type E or XMRP, work schedule, acct. and costing data

Material status (MARA and MARC)

The material to be produced must have already been designated procurement type in house production(X,E).

The material status must be released for production on both a cross-plant level (MARA) and a plantlevel (MARC) .

At least one plant specific view (MRP and/or work scheduling) as well as financial accounting andcosting views must be maintained for the material.

You prepare BOMs as single level BOMs . A special selection procedure chooses the correct BOM. After you have prepared a routing, a special selection procedure chooses the correct one.


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ProductionProduction

Production operator Production scheduler

(supervisor)

ProductionpreparationProductionpreparation

Docu. &analysisDocu. &analysis

Industrialengineer

Salesplanning

Salesplanning

Designengineer

Plantreqmts

DetailedPlanning

Production planner Plant manager MRP controller

Production scheduler

Production operator Production scheduler

Plant manager Quality

inspector

Order-Related Production - Roles

Within the development of the SAP product " mySAP.com ", computer-supported work centers have been created along the entire process chain for order-related production.

Production order management touches on at least those roles shown on the slide. Individual roles are assigned different activities (tasks), authorizations and responsibilities that

correspond to the actual daily work carried out in practice.


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Production Order - Symbol Overview

Order header

Detail screen (operation , comp onent, PRT, ...)

Sequence overview

Component overview

Operation overview

Document overview

Status overview

Key

Collective order ov erview

Log

Trigger point overview

Change

Display

Save

Deletion

Schedule (order, collective order)

Cost

Check availabili ty (material, capacity, PRT)

Release (order, operation)

Print

Enter long text (text editor)

Generate object (for example, order)

Execute program (function)

Update

The slide shows the most frequently used pushbuttons (symbols) in the production order. The symbols have been arranged on the individual production order screens in such a way that you can

always find the relevant symbol in the same place on the screen. Order functions are arranged on the left and navigation function s on the right . In the overviews of the operations, components and production resources/tools, the relevant pushbuttons

for the individual object have been arranged underneath the overview . Where it was considered appropriate, pushbuttons were placed directly next to a data field.


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Order type

LO215 - Commonly Used Abbreviations

Table T399XSPRO + SFC + Master Data + Order-TypeDependent Parameters

Order type parameters

Table T003OSPRO + SFC + Master Data + Order Types

PP-SFC

Scheduling parameters ofthe order type

Table TCX00_FASPRO + SFC + Operations + Scheduling + SchedulingParameters

Production Planning - Shop Floor ControlSAP + LO + PP + Shop Floor Control

Customizing Transaction SPROSAP + Tools + Accelerated SAP + Customizing +Edit Project

Task menu (SAP) Transaction sess ion_manager

During the LO215 course, the instructor may repeatedly use certain terms, tables and shortcuts . Theslide contains the most important terms and their menu paths.

The instructor will not always repeat these menu paths.


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Order data structureProduction order screens

Overview of order processing

Order Structure and Processing: Contents


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Order Structure and Processing: CourseObjectives


Describe production order data structure

Describe the most important production orderscreens

Summarize the main functions of order processing


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33




55




OverviewOverview 22

Order Order StructureStructure //ProcessingProcessing


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Elements of an Order

Order header Order header

OperationsOperations

Capacity spl itsCapacity spl its

MaterialMaterial componentscomponents

ProdProd .. resourcesresources //toolstools

Trigger PointsTrigger Points

ConfirmationsConfirmations

Order number

PlantProduction scheduler

Work center Control key

Standard values

Individual machineIndividual person

Settlement ru leSettlement ru le

Settlement profileSettlement receiver

Material number QuantityReqmts date

PRT number PRT category

Number

Functions

QuantitiesTimes

CostsCosts

Planned Actual

Document linksDocument links

Doc. number Doc. category

OperationOperation sequencessequences

Standard sequenceOther sequences

The order structure can be enhanced by adding certain elements. At least one operation is required. The system automatically creates this operation when missing. You have the choice of whether or not to assign material components, production resources / tools

and trigger points to the operation. You can create several (parallel) operation sequences. You can make a selection from several alternative sequences . Suboperations are permitted within an operation. Costs are determined at operation level and submitted at order header level only in the case of order-

related cost object controlling .


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Production Order - Header

1000767

General Assignment Goods receipt Control Dates/quantities Master data

Order typeOrder number PlantMaterial or activityQuantit ies dates

To RoutingTo BOMTo Costing

Entered by / Changed byPlants

Assign men tsMRP controller

Control of goods receipt

Movement typeSettlement rul eSettlement receiver Percentages

Deadline monitoringQuantity m onitoring

Product (activity) to bemanufactured with the order

ManualPlanned order

Definition Origin

Order Edit Goto Header Functions Environment

The segment of the order header describes the product that is to be manufactured with the productionorder (finished product, assembly, individual part).

There are a series of detail screens for the order header. The header text of a production order can either be the short text of the material master or the header

text of the routing that has been copied into the production order (with reference to this, see the switchin table T399X ).


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Production Order - Operation

1000767

Stand. values Ext. processing Interoperation times Standard value calc.

Operation 0010

Operation overview

Single step inOrder

ManualRouting

OperationSuboperation

Definition Origin Types General Data

Standard values

Ext. process ing

Interoperation timesStandard values calc.SplittingOverlapping

Operation dates

User field sQuantities/activitiesConfirmed dates

Order Edit Goto OperationFunctions Environment

GeneralData

This segment of the operation describes the individual work steps of the production order. There are a series of detail screens for an operation. These screens, in turn, incorporate further detail screens .

For example, you can branch from the component overview to screens for each material component. You have the option of inserting suboperations hierarchically with reference to an operation.

This enhances calculation and capacity planning .The operation control key of the sub-operation plays an important role in this.

Scheduling always occurs at operation level . The standard values of the suboperations can be cumulated on the corresponding operation when the

dimension and units of measurement are the same. It is not possible to assign material components or production resources / tools to sub-operations.


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Production Order - Material Components

1000767

Purch.data VarSzeltmDta Co-product Text item

Compon. 0010

Material number Material descriptionRequir ements qtyReqmts date

ReservationItem categoryBulk mat. indicator

Availab le quant ity

Issued quantityMissing parts quantity

Text editor

OriginDefinition

Materials required for anoperation or for manufacturinga product

Manual

BOMPlanned order

Order Edit Goto ComponentFunctions Environment

General data

In a production order, you can assign any number of material components to an operation. The segment for the material component describes the material required to carry out the individual

operations. There are a series of single screens for a material component.


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Production Order - Production Resources/Tools

Definition

1000767

General Quantities Dates

Item 0010

TypesOrigin

PRT number PRT control keyPlant

Requirements q ty

Usage valueFormulasUsage dates

Document (graphics)PRT text

Production resources/tools requiredto execute an operation Manual

Routing

MaterialEquipment(as of 3.0)DocumentOther Order Edit Goto PRTsFunctions Environment

In a production order, you can assign any number of production resources/tools to an operation. The segment for production resources/tools describes the required devices, tools, test equipment and so

on required for executing an individual operation. The production resources/tools category is essentially derived from the demands on a production

resource/tool and its relationship to a certain object (material, equipment and so on).


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Production Order - Documents

P-100

Order Processing Go to DocumentFunctions Environment

Doc. Data Additional Data Descriptions Object Links Original

Document

Document no.SubdocumentDocument version

Assignmt to oper ationOriginFormat

Object link

Original appl . file(s)

Storage data

Definition

Production resources/tools required

execute an o rder

Origin

Manual

Material Master Bill o f MaterialProd.Version

000 00

Originals

You can assign any number of documents to a production order. These are maintained in theDocument Management System (DMS).

The documents themselves are only linked to the production order and not saved in it. You can create links from documents to a production order manually or automatically . Documents can be drawings, texts, videos and so on. Application example: Product descriptions

Assembly instructions and diagramsInspection instructions and certificatesWork instructionsStorage and transportation regulationsSpare parts lists

Maintenance regulations


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1000767

Costs arising during theexecution of a production order

Aut omaticCosting

Definition Origin

Order Edit Goto Header Functions Environment

Production Order - Costs

OverheadOverhead costscostsCalculated in overhead structure

Production costsProduction costsIn-house production

Activi ty pr iceaccording to valuationvariant

Ext. processingPrice acc. to valuationvariant

MaterialMaterial costscostsStock materialPrice d eterminationaccording to valuationvariantNon-stock materialPrice from purch. info record

Process costsProcess costs Ass ig ned acc. to template

Itemization Cost categories Cost comp. structure

If order-related cost object controlling is used, each individual production order has a cost object(CO).

Order costs can be calculated manually or automatically .You define this by setting up the order-type dependent parameters accordingly in Customizing (tableT399X).

The CO object enables you to display different lists of costs for a production order. By choosing Goto + Costs in an order, you can find lists for the terms

Itemization (detailed overview of the individual costing items)Analysis (overview structured according to cost category)

Cost component structure (overview structured according to arithmetical cost components)


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Production Order - Settlement Rules

OperationsOperations

Material componentsMaterial components

Prod. resources/toolsProd. resources/tools

Costs PlannedTarget

Ac tual

Costs PlannedTarget

Actual

2050

100


Definition

Material

Cost center

CO order

Asset

WBS element

Sales order and so on

Manual

Aut omatic

Receiver of order costs

Account assign ment categor ies

Origin

You control order settlement by way of settlement rules . The order can be settled proportionally to one or more receivers . Settlement rules are created manually or automatically (during order creation).

At the latest, they must be maintained before the goods receipts posting is carried out for the material to be produced.

You define the settings for order settlement in Customizing. If you use product-related cost object controlling , the settlement rules are contained in the product

cost collector and not in the production order .


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Processing a Production Order

11Order request

Order creation

Availabi litychecks

Print o rder

Material st aging

Order settlement

Archiv in g / deletin g

Goods receiptOrder release

Confirmations

2050

100Determine WIP

Calculate variances

Order processing

Machinereservation

22

33

44

55

66

7788

99

1010

1111

1212

1313

1414


Operations

Materialcomponents


Costs PlannedTarget

Actual

The production order runs through a wide range of individual activities . WIP calculation, variance calculation and settlement are generally periodic operations for cost

object controlling that are processed in the background . You must define a series of settings for each individual stage if an order is to be processed successfully. CO Configuration includes a special feature that sets the prerequisites for WIP determination, variance

calculation and settlement.


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Order Structure and Processing: Summary

You have gained an overview of the data structureof a production order

You know the most important production orderscreens

The basic functions of production ordermanagement were shown in an example


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Exercise Data

Note:

There will not be sufficient time to work throughall the exercises during the course. The exercisesmarked Optional should be seen as supplementaryexamples that can be used, as required and time

permitting, during the course. Attendees can alsouse these exercises after the course, to consolidatewhat they have learned.

Explanation of the Symbols in the Exercises and Solutions

Exercises

Solutions

Course Objectives

Business scenario

Tips & Tricks

Warning or caution


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Data in the exercises

Type of data Data in training system(ID3, client 400)

Data in the IDES system (ID3, client 800)

Group no. xx (01....20)

User master records LO215-xx passwordFERT

Client 400 (401, 402) as pertraining room

Customizing project 200 200

Company code 1000 1000

Business area 1000 1000

Purchasingorganization

1000 1000

Sales organization 1000 1000

Distribution channel 10 Final customer sale 10 Final customer saleDivision 00 Multiple division 00 Multiple division

Sector M Mechanicalengineering

M Mechanicalengineering

Personnel area 1000 1000

Personnel subarea

Chart of accounts INT INT

Controlling area 1000 1000

Cost center hierarchy H1 H1

Cost center nodes 4200 4200


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Cost centers 4210, 4220, 4230 4210, 4220, 4230

Activity types 1410 Machine time

1420 Setup time1430 Personnel time

1410 Machine time

1420 Setup time1430 Personnel time

Factory calendar 01 01

Plants 1000 (Normal)

1100 (special structures)

1000 (Normal)

1100 (special structures)

MRP controllers 100, 101 Demo

001 to 002 Participants

099 Instructor

100, 101 Demo

Capacity planner 100, 101 Demo


099 Instructor

100, 101 Demo

Production scheduler 100, 101 Demo


099 Instructor

100, 101 Demo

Production scheduling profile

0000001 Normal

0000002 automatic

0000001 Normal

0000002 automatic


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Normal flow

Collective order

Config.var. scn. 1

Config.var. scn. 2

Config.var. scn. 3Changemanagement

Normal flow

Rework

Automat.Procedure

Limited no. ofVariants

W/o BOM and plan

Select. BOM/plan

Op. consequences

Co-products

Mat. components

Mat. staging

Availability

Discontinued parts

Cross-plant

Split valuation

Batch production

Ext. Proc. / proc.

Serial numbers

Repetitive /order- based production

Stockdetermination

P-100

P-400

P-500

P-501

P-502P-600

100-300

100-301

T-A

T-V1, V2

T-MAN

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

T-STOCK

P-100

P-400

P-500

P-501

P-502P-600

100-300

100-301

T-A

T-V1, V2

T-MAN

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

T-STOCK


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Bills of material T-F1xx

P-100P-400

P-500

P-501

P-502

P-600

T-A

T-V1, V2

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

P-100P-400

P-500

P-501

P-502

P-600

T-A

T-V1, V2

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

Routings T-F1xx

P-100

P-400

P-500

P-100

P-400

P-500


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P-501

P-502

P-600

T-A

T-V1, V2T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

50000003 standard tasklist

P-501

P-502

P-600

T-A

T-V1, V2T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

50000003 standard tasklist

WM storage bin PROD-1310 PROD-1310

Standard trigger

point

T-NACHARB T-NACHARB

Order types PP01 Demo andexercise

PP03 Demo andexercise

PP04 Demo and

PP01 Demo

PP03 Demo

PP04 Demo

PP06 Demo


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PP Exercise Material - BOM T-F1xx

T-F1xx (FERT, P-100)(1000, 0, _ )

1 81

T-T1xx(ROH, 100-110)(1000, 1000, 2 )

T-T2xx(ROH, 100-120)(1000, 1000, 2 )

T-T3xx(ROH, 100-130)(1000, 1000, 2 )

1

T-T4xx(ROH, 100-310)(1000, 1000, 2 )

1

T-B1xx (HALB, 100-100)(1000, 10, 2 )

1

T-B2xx (HALB, 100-200)(1000, 10, 2 ) (1100, 10, 2 )

1

T-B3xx (HALB, 100-300)(1000, 0, _ )

1

T-B4xx (HALB, 100-400)(1000, 10, 2 )

T-T0xx(ROH, 100-210)(1000, 1000, 2 )

1

(1100, 1000, 2 )

Key: (Material, IDES template)

(Plant, stock qty, sec. reqmts ind.))

Item 00 10 0020 0030 0040

1

T-T5xx(ROH, 100-410)(1000, 1000, 2 )

os. 00 10 0020 0030 0010 0010 0010

1

Dokument T-F1xx DRW, 000, 00

0050


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SAP AG 1999 titel (author) 2

PP Exercise Materials - Routings

not a ssigned

10TP-Lxx( 1310 )

0010T-Mxx( 1310 )

0030 T-Lxx( 1906 )

0020T-Vxx( 1320 )

0040 T-Exx( 1904 )

0050T-Fxx( 1721 )

0060 T-Pxx( 1721 )

T-VHhierarchy:

T-V

Assignm ent tosta t . work center

a nd hierarc hy

T-EHhierarchy:

T-E

T-F1xx(FERT, P-100)(1000, 0, _ )

T-F2xx(FERT, P-100)(1000, 0, _ )


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Order Structure and Order Processing Exercises

Unit: Order Structure and Order Processing

Topic: Order Structure and Order Processing(LO215 Exercise 1)

Structure (data and contents) of a production order

In your capacity as production manager, production scheduler,supervisor or operator, you work with production orders all thetime. In this exercise, you will become familiar with the structureof a production order.

1-1 Display the production order no. _______________ .

Path: S000 LO PP SFC ORDER DISPLAY

1-2 Display the individual data segments, screens and their data fields in the followingorder:

Note any questions you may have about the meaning of the data fields.

If the meaning of any of the data fields is not clear, ask the instructor.

1-2-1 Order header screens

Path: GOTO HEADER


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Select the corresponding tab index for the respective screen.

GeneralAssignmentGoods receipt

ControlDates/quantitiesMaster dataLong textSettlement rule

Path: HEADER SETTLEMENT RULE

1-2-2 Overview of the operation sequences

Path: GOTO OVERVIEWS SEQUENCES

1-2-3 Operation sequence details

Path: SEQUENCE DETAILS

1-2-4 Operation overview

Path: GOTO OVERVIEWS OPERATIONS

1-2-5 Operation screens (select operation " 0010" )

Path: OPERATION OPERATION DETAILS


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GeneralStandard valuesExternal processingInteroperation times

Standard value calculationSplittingOverlapDatesUser fieldsSuboperation/datesQuantities/activitiesConfirmed datesQualificationLong text

1-2-6 Material components - Overview

Path: GOTO OVERVIEWS COMPONENTS

1-2-7 Material component screens (select component " 0010" or "0070" )

Path: COMPONENT COMPONENT DETAILS


Item 0010 General Data

Item 0070 VarSzeltmDta

1-2-8 Overview of production resources/tools for operation "0050"

Path: Go to the operation overview and select operation "0050".

In the menu bar at the bottom of the screen, select the PRT pushbutton(Production resources/tools)

1-2-9 Screens for the production resources/tools (select production resource/tool"0020" )


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Path: PRODUCTION RESOURCE/TOOL PRODUCTION RESOURCE/TOOL DETAILSHILFSMITTEL


Item 0020 GeneralQuantitiesDates

1-2-10 Document overview

Path: GOTO OVERVIEWS DOCUMENTS

1-2-11 Display of the document information record (select the first document)

Path: DOCUMENT DISPLAY DOCUMENT INFORMATION RECORD


Document data

Additional data

DescriptionsObject links

Original

1-2-12 Display of the original document (display both originals from the documentoverview for the order)

Path: DOCUMENT DISPLAY ORIGINAL DOCUMENT

1-2-13 Costs

Itemization

Analysis (Cost categories)

Cost comp. structure (Cost component


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Order Structure and Order Processing Solutions

Unit: Order Structure and Order Processing

Topic: Order Structure and Order Processing(LO215 Exercise 1)

No answers are required for this exercise.


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Order Creation/Order Change: Contents

Function procedure "Creating an order" Automatic follow-on post ingsCreation variants

NormalWith production versionNo reference to material (any activity)Copy from order Related to sales order

With variant configuration

Bill of material and task list selectionConverting planned ordersReading master dataOperation sequences in an order


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Order Creation/Changing Orders: CourseObjectives

Define the basic features and variants for creating production ordersDescribe subsequent functions in order creationDescribe the process of routing and BOMselection when creating an order Define how master data is read intoexisting ordersDescribe how to create and convertplanned orders

SAP AG 1999


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1212









55

44


Order Order CreationCreation //Order ChangeOrder Change

OverviewOverview 22



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Creating Production Orders

FridayJuly

27 1992

TuesdayDecember

18 1992

ManualManual Requirements planningRequirements planning Aut omatic Aut omatic

Specify order type

Define order item

Copy routing

Copy bill of material

Lead time scheduli ng

Optional (Customizing)

Availabi lity check

Add, change

Save producti on order

Various functions (1)(1)

The production order can be generated automatically (confirmation, sales order) or manually (directly) by converting it from a planned order .

A start / finish date is entered for the order item (product) according to the scheduling type (forwards or backwards) .

Lead time scheduling is executed automatically. It calculates the start / finish dates of the order and thedetailed dates and capacity requirements of the operations.

You also have the option of carrying out an availability check (specifiable in Customizing). You can determine the planned costs when saving the order (specifiable in Customizing). ((11 )) Other functions that can be executed automatically are:

Batch creation, determination, order classification, serial number assignment, document integration.


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Automat ic Postings

MaterialMaterial reservationsreservations

Purchase requisitionsPurchase requisitions

CostsCosts (CO object)(CO object)

Capacity r equirementsCapacity r equirements

TransportTransport requirementsrequirements

Inspection l otsInspection l ots

PRTPRT requirementsrequirements

Inventory management

Purchasing

Controlling

Capacity planning

Warehouse management

Quality management

PRT management

When you create a production order, a series of additional posting procedures occur at the time ofposting (the data is already formatted online).These automatically generate the required data for stored parts of the system .

Material reservations are generated for all warehouse components. You can choose whether thesereservations are to be immediately relevant to MRP or not until the time of release (indicator in theorder-type dependent parameters T399X)

Purchase requisitions are created for non-warehouse components and externally processed operations. Costs are determined when you save . Transport requirements are generated when the operation is released . PRT requirements are only generated internally. At the present time, however, there is no

requirements planning for PRTs which works with these records.

Transaction CF21 (using PRT in orders) is available for evaluating PRT requirements in productionorders.

Missing parts records are written for missing parts.


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Creation Variants 1

2050

100

Activi ty

Directly (manually)From planned order

Copy from order

For sales order

From SD (assembly order)

From confirmation(rework)

As co ll ect ive order

With variant configuration


Operations

Material components


PlannedTarget

Actual

Costs

With reference to material

Without reference to material

There are numerous possibilities for creating production orders.


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Creation Variants 2

Order

Order

Planned

Planned Order

Material BOM

Order Planned order

Planned

Create without routing andbill of material

Create with routings

Create with r outingand b il l of mater ial

Create with plann ed order

Operations, material components and production resources / tools are normally copied from the routing and BOM .

You can also input such information manually . The BOM is not reread when you convert a planned order. If you do not specify otherwise in a routing, the system automatically assigns the BOM components to

the first operation .


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Own scheduling for planned ordersTo the dayCalculated basic dates Basic start date

Basic f inish dateCreation date

Base in-house production time or replenishment lead time Advantageous f or per forman ceNo capacity requirements are determined

UsedTo the second

Starts from basic dates Requirem ents planningManual

Determined pr oduction dates (scheduled dates)Start d ateFinish dateRelease date

Base operationsDetermined capacity requirements

Material requirements planning

Lead time scheduling

Periods


Operations

Materialcomponents

Prod.resources/tools

Costs PlannedTarget

Actual20

50100

for orders and routings

Scheduling in Production Planning

Production planning has two scheduling methods that are used differently and have different results: Scheduling of planned orders in material requirements planning (calculates the basic dates only) Lead time scheduling (starts from the basic dates and calculates the production dates)

Only lead time scheduling calculates operation-related dates and capacity requirements. Lead time scheduling is the basis for

Order scheduling Routing scheduling Scheduling in applications PS, PM, PI

In addition, lead time scheduling can be activated in material requirements planning in order todetermine capacity requirements for planned orders.


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Number Assignment for a Production Order

. . . .

1000000100000019999991999999

2000000200000029999992999999

3000000300000039999993999999

PP02PP02PI02PI02..........

XX

PP01PP01IDESIDESPP06PP06........

PI01PI01............

Number rangeNumber range objectobject for for anan order order ((generalgeneral ))

Range fromto

Assignment in ternalexternal(x)

Assignment of th eorder types(element)

Number range -Group 1



Order numbers are assigned according to order typ e. Numbers can be assigned either externally or internally . The order number can be composed of a maximum of 12 characters . Order numbers can be defined independent of company codes, plants and other organizational

structures. A number range group must be specified for each predefined number range. You can create an

unlimited amount of number range groups. The order categories can be assigned to any of the number range groups. The system does not allow

multiple assignment. The current status of the internal number assignment can be changed manually provided that the

sequences are taken into account. You maintain the number range in Customizing.


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Task List Selection Criteria

Selection type (T399X) " With / without routing""Routing required / optional""Manual / automatic selection""With / without ref. operation set""P" (Production)"N" (Normal) " S" (Standard)

Task list usageTask list type

Task list selection IDUsage

Material no.Plant

" Alternative selection" indicator (MRP screen 4)

Production version

GroupGroup counter StatusValidityLot-size rangeDeletion flag = = "X"

"Order quantity""Basic start/finish date""Released"

(in reference operation sets)

CustomizingCustomizing

Routing

Material

A

"Production version" indicator (T399X)

You define the routing selection options in Customizing . The most important tables are :

T399X order-type dependent parameters andTCA43 automatic selection

You can determine whether a routing is necessary or not (selection type). All criteria are always checked and a routing is only selected if all criteria are fulfilled. Determining which validity the routing should be selected with is dependent on the setting in table

T399D ( Customizing Requirements Planning) .


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BOM

Stage

0

1

2. . .

. . .

20

50100

HEADERHEADER

ITEMITEM

ITEM

PumpP-100

Pre-assembled casing

100-100

Pre-assembled shaft

100-300

Casing

100-110

Support base

100-700

Shaft

100-301


Operations

Material components


PlannedTarget

Actual

Costs

BOMs contain the material structure and required quantities of the individual components for a product. The required quantities are not dependent on the order.

BOM data is copied to the production order . Subsequent changes you make to the BOM do not takeeffect on orders that already exist.

When you create an order, a BOM is chosen on the basis of the corresponding selection criteria . The BOM is exploded on one level . An exception to this is multi-level BOM explosion for so-called phantom assemblies . Subitems are not copied to the order.


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Bill of Material Selection - Procedure

BOM alternativealternative (T415A)

Addi tion alcriteria

= Blank

=

No

= 2

=Yes

= 1

Sel. ID

Mat. master Indicator " Alternative

selection"

PP parameters for order type (T399X)

"BOM usage"

BOM usage(TC04)

BOM selection bylot size

BOM selection bydate

Selection b ydate permitted ?

BOM selection byPV

Selection b yPV permitted?= 3

Mandatory BOMselection by PV

Key:PV = Productionversion

BOM usagepriorities (TCS41)

PP parameters for order type (T399X)

"ProdVersion" indicator

BOMBOM

BOM

= Yes

= No

During automatic selection, the alternative selection indicator in the material master (MRP screen 4)determines the selection procedure.

Note the following special features: IND = Blank

The system takes the BOM usage that is defined for each order type from table T399X , enters tableTC04 with this and takes a selection ID from this table. The system uses this selection ID andsearches the sequence of priorities contained in table TCS41 for the first available BOM that fulfillsthe lot size and BOM usage criteria .

IND = 1Selection according to date requires that an entry is maintained in Customizing for the material(T415A a lternative selection multiple BOM).

IND = 2The system searches the material master for production versions that fit the lot size .If only one exists, then its BOM is checked against all criteria (also those contained in TCS41!). Ifthere are more than one , table T399X decides ( production version indicator) whether the user(dialog box) or the system (automatic) determines which production version is to be selected. If,despite this, no valid BOM is found, the system does not stop .The system carries on searching using the procedure for when the indicator is "blank".

IND = 3Same as for value = 2 . If no valid BOM is found in this case, the system stops searching!The production order has no components.


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Selection according to production version presupposes that valid production versions have beenmaintained in the material master.


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Item Categories in the Production Order

2050

100

Reservation

Purchaserequisition

Find objectfor class


Operations

Material components


PlannedTarget

Actual

Costs

Stock item

Variable-size item

Non-stock item

Text item

Class i tem

Item categories control the data scope and functions of a material component. Typical examples are:

Stock item Non-stock itemVariable-size itemText itemClass item

You cannot make alterations to item categories once they have been set. Follow-on documents are generated with the production order according to item category. Components with the item category "non-stock item" automatically generate a purchase requisition.

This can be displayed for an item via a further screen. The class item stands for a wide variety of different materials. When you enter the command "find

object function for class", the system can specify the class item in a particular stock item. The "document item" is transferred to the document list of the production order (document link)


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Reservation

1

Material A

Reservation

Header

ItemItem

ItemItem

ItemItem MaterialPlant / Storage location

Reqmts dateMovement allowedCommitted qty

Base date

Check calendar

Assign ment

The system generates material reservations for all material components of a production order of the type "stock material" .

Reservations are taken into account when determining the conditions for material requirements planning. Reservations are also taken into account when creating goods movements for components of the production order.

A reservation item applies to a plant or a plant's storage location . A requirements date is defined by the order for each item. You can control whether goods movements

are allowed for the reservation item by means of an indicator. The reservations for material components of the production order are assigned to this production order. You can compile lists of reservations for the material or account assignment (production order).


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Material Assignment

Item 20

Item 10

Op.30

Op.20

Op.10

MaterialB

Material A

Routing BOM

You can assign material components to operations both when managing BOMs and routings . The assignment of material components to operations is copied to the production order. If no assignments are maintained, then the system automatically assigns the BOM material

components to the leading operation . When you display the material components overview , you can assign material components to

individual operations and display material components. The material components list can be sorted andfiltered according to various criteria in order to enhance this overview.

Other functions include:Assigning, reassigning and deleting material assignments. Navigating between operations

You are able to reassign materials up to the point of order release .


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Assignment of Production Resources / Tools

Production order

Op.10

Op.20

Op.30

PRT1

PRT2

You can assign production resources/tools to every operation in a production order. Production resource/tool assignments are copied from the routing to the production order.


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SAP AG 2003

Document Integration in Production Orders

Production order

Routing

BOM

DMSMaterial

B

Master Data Document ManagementSystem (DMS)

Material item 10

Document item 20

Document item 30

Operation 10

Operation 20

Document 1

Document 2

Document 3

Prod. res./tools Production res/tools

Order item

Overview of documents in PrO

Document 4

Document 5

Document link 4

Document link 5

Document link 1

Material item 10

Operation 10

Operation 20

Document link 2

Document 6

Fri

Fri

Fri

Fri

You can assign any number of documents to a production order. These are maintained in theDocument Management System (DMS).

Documents can be drawings, texts, videos and so on. The documents themselves are only linked to the production order and not saved in it. You can create links from documents to a production order manually or automatically . Automatic linking of documents takes place during order creation or release. The document items are

copied from the BOM, the production version or from the document link to the material master ofthe product to be manufactured.(This must be activated in the production scheduling profile - Customizing for Shop Floor Control)

Document links in the production order created in this way can be displayed, changed, deleted, printed(separate list), archived and displayed in the product structure browser .

Original document s cannot be printed out. All document types that you use must be permitted for object PORDER (production order), work with

status management and must be released. (See Customizing for the Document Management System). Examples, see above:

Document 1 Link copied from material masterDocument 2 Link created manuallyDocument 3 No link to production orderDocument 4 and 5 Link created from BOM itemDocument 6 does not appear in the document overview of the production order


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Operation Sequences in a Production Order

Product AOrder header

Sequence typesStandardStandard

sequencesequence 00000000 Alternative Al ternative

sequencesequence 00010001

ParallelParallel sequencesequence00020002

Op. 70

Op. 80

Op. 10

Op. 20

Op. 30

Op. 40

Op. 50

Op. 60

Op. 10

Op. 15

Op. 20

Op. 70

Op. 80

Op. 90..

Alternative and parallel operation sequences are possible in production orders. The alternative sequence gives you the option of choosing alternative operations for a sequence of

operations. The parallel sequence enables you to process operations parallel to and independent of other operations. You can copy both sequence types in an order from a routing (via Customizing).


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Alternat ive Sequences

> 20

25

< 30

Operation 10

Operation 20

Operation 30

Operation 40Operation 50

> 10

15

20

25

< 30

Alternative Alternativesequencesequence 00020002

StandardStandard sequencesequence00000000

Alternative Alternativesequencesequence 00010001

Alternative sequences are linked to the standard sequence. An alternative sequence can be created automatically when you create a production order or read the

master data. You can use the " exchange sequences" function to replace alternative sequences with a different

sequence . This exchange is possible as long as certain functions have not yet been executed .

For example, material withdrawals, confirmations, purchase orders . A switch is only possible if:

The standard sequence has branch and return operationsThe operation numbers are within the standard sequence rangeThere is no overlap with other alternative sequences.

Application: Changed work procedures with different lot sizes and capacity bottlenecks(external processing).


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Parallel Sequences

20 25 30

30

20 30

40 50 60

45 55

IIIII

IIIIIIIII

IIIIIIIII= Floats

IIIIIIIII

Parallel sequence 1

Parallel sequence 2

Parallel sequence 3

Operation 10 Operation 20

Alternative and parallel operation sequences are possible in production orders. The parallel sequence enables you to process operations parallel to and independent of other operations. You can copy both sequence types in an order from a routing (via Customizing). Parallel sequences are linked to the standard sequence through predecessor / successor

relationships . Parallel sequences are a special form of overlapping operations. Parallel sequences create network-like structures. Order scheduling inserts operation floats according to the alignment key specifications. Applications:

In mechanical engineering for assemblies involving the production of individual components, inspection processes, and preparatory and closing operations. In the chemical industry for analysis processes that

are carried out in parallel to the production process.


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Read Master Data

2050

100

Routing 2

BOM 1

BOM 2

Routing 1

Material components


Operations


PlannedTarget

Actual

Costs

You can use the function "Read PP master data" to switch the originally copied routing 1 and / orBOM 1 with a different routing and / or BOM alternative 2 .

This exchange is possible as long as certain functions have not yet been executed .For example, material withdrawals, confirmations, purchase orders .

Assignments of components (BOMs) and production resources/tools are retained, provided that thecorresponding operation still exists.

This function can also be used for collective orders (refer to the "Collective Orders" unit)


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Order Change Management(OCM)

Aims of change management for production ordersProvision of a system-supported tool for automated change of productionorders which are already being used in the production process.

The changes concerned can be triggered by changes in sales orders and/or master data

When are the OCM tools needed?Production orders are already being used in the production process and havebeen worked on

Customers change their order

Engineering or technological changes are necessaryMass orders are affected by changes (for example, collective orders)

Who needs the OCM tools?Sales-order-related production, make-to-order production

12

9

6

3

11 1

7 58 4

210

SAP AG 1999

If you wish to change orders already being used in production and the options provided by the "ReadPP master data" function do not suffice, you can use Order Change Management for productionorders (OCM) (as of Release 4.5).

The R/3 change management function enables the user to make changes that are coordinatedthroughout the order process, in terms of content and dates , to one or more objects (product masterdata and documents from business transactions currently in process).

Change management differentiates between:ECH = Engineering Change Management OCM = Order

Change Management ECH concentrates on the preparation and execution of changes to product master data. OCM concentrates on the exection of changes to production orders that are already being used in the

production process (and on finding planned orders or purchase orders that are affected by thesechanges).

The changes in OCM are based on changes from the area of product master data (ECH), as well ascertain changes from sales orders (SD).

You cannot carry out automatic unchecked changes to production orders that are currently being usedin the production process (for example, material consumption has been posted, order is partiallyconfirmed,...). This is why the R/3 system provides functions for the controlled change of orders.

Change management for production orders (OCM) is dealt with in detail in course LO980 .


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Order Creation with Planned Orders

Inspection l otInspection l ot

Planned order Planned order

RoutingRouting

Production order Production order

Order item Material components

Inspection data Operations PRT

Material number (Product)Requirements qtyReqmts date

Material number (component)Requirements qty

Inspection characteristicsTest values/characteristics

Op number Work center Control keyStandard values

PRT number Requirements qtyControl key

Planned orders are created via Material requirements planning (MRP ). Creating production orders from planned orders is the most important function of the whole PP

application. When you create a production order from a planned order, the system automatically supplies the production order data .

When an inspection lot is generated, the inspection data is copied from the routing but not written tothe production order.


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Material Requirements Planning (MRP)

MRP area: Plant

Material A

Planning unit Planning run types Processingkey

NEUPL

NETCH

NETPLNet change planningin the short-termplanning horizon

Net change planning

Regenerative planning

Material requirements planning is executed at the level of the MRP area (plant, warehouse, ...). Regenerative planning means that you plan all materials from the planning file. Net change planning means that you can only plan materials which are already entered in the

planning file and have therefore undergone a change relevant to MRP. Planning file entries can be generated either automatically or manually. Net change planning in the short-term planning horizon means that you can only plan materials that

have already undergone a change relevant to MRP within a restricted planning horizon . You can onlygenerate order proposals within the planning horizon.

Planning can either be carried out online or in the background . Material requirements planning (MRP) is dealt with in detail in course LO210 .


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Planned Order Structure

1000767

Header Assignment Master Data

Plnd order Processing Goto Extras

Material A

Requir ed material- Quantity- Requirements date

Items

Order typeQuantityDates

Detailed sched.Components

Capacity r eqmts- Operation- Work center - Reqmts date

PeriodsPeriodst

Capacity r eq. records

R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R /

3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3 R / 3

Planned receipt of the net requirements calculation for requirements coverage. Requirements transfer object for the dependent requirements. It can be used as a pegged requirement for capacity planning. It provides a data source for the production order.


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Multi-Level Materials Planning

PlannedPlanned --SalesSales --

PlannedPlannedindependentindependentrequirementsrequirements

PLANNED ORDER

PLANNED ORDER

PLANNED ORDER

Dependent requirementsDependent requirements

Dependent requirementsDependent requirements

E1E1

B1B1 B2

R1R1 R2R2 R3R3

Requirements planning covers a whole product structure. It runs in the following steps for eachmaterial. Checking the requirements coverage. Generating the planned order. Determining the dependent requirements. Entering the components into the planning file.


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MRP List

Header

Net planning

Single item planning

Storage location planning

Material

MRP parameters

- Items

- Items

- Items

Planning result

ContentsContents

Purchase requisitions

Planned orders

MRP list

An important result of material requirements planning is the MRP list . An MRP list is created for each MRP related material . Current stock and requirement situations are displayed as of the last planning run . The MRP list is subdivided according to different planning segments . Changes made between two planning runs are not displayed. Error messages are copied to a log.


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Current Stock/Requirements list

Production orders

Header

Net planning

Single item planning

Storage location planning

Material

MRP parameters

- Items

- Items

- Items

Stock/reqmts list

Purchase requisitionsPurchase ordersPlanned ordersSales ordersReservationsWarehouse stock

ContentsContents

MaterialMaterial

A further result of material requirements planning is the current stock / requirements list . This list displays the current and therefore up-to-the-minute stock / requirements situation . You can generate the list dynamically by directly reading the MRP elements. From this list, individual planned orders can be converted to production orders .


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Collective Conversion - Time-Oriented

Operations

Materialcomponents


Costs PlannedTarget

Actual

Purchaserequisition

Planned o rders

PD

PS

PO

PD

PS

PO

t

x Days later

Today

x Days earlier

Production orders

Opening period

Reqmtsplanning


2010050

You can convert planned orders online either individually , collectively, completely or partially . You can convert planned orders in the background using the program PPBICO40 . Planned orders consist of a planned order start date (PS), a planned order finish date (PL) and a planned

order opening date (PE). When the planned order opening date is reached, you should convert the planned order into a production order or a purchase requisition.

When you convert a planned order into a production order, the planned order is deleted . The system reassigns the dependent requirements (material components) and any existing capacity

requirements to the newly created production order. By changing an indicator, the dependent requirements can then be turned into a reservation . When a planned order is only partially converted , it remains intact and is fixed . You can perform a collective conversion that is dependent on the outcome of a material availability

check (analogous to the order release).


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Converting Planned Orders - Time Frame

R1R1 B1

E1E1R2R2

R3R3

B2

t

Total lead time

Opening periodOpening period ((fromfrom -- to)to)

CurrentCurrent datedate

The MRP controller uses the "collective conversion" function to convert the planned orders of a product structure falling within a set time period.

In the framework of an entire product structure , the system will only convert those planned orderswhose planned order opening dates are within a defined opening period .

You can predefine the size of the opening period with reference to the current date in User Parameters(AEV, AEB) .

This procedure is particularly suited to deterministic make-to-stock production.


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Collective Conversion - Structure-Oriented

Prod. order 2

Prod. order 1

Preq

Prod. order 4

Prod. order 3

As an alternative to time-related collective conversion, the order progress report provides the "Convert planned orders" function for structure-related conversion .

An order progress report is available in Release 4.5. It enables you to clearly chart the progress of all business transactions (in-house production and external procurement) that are required when carryingout a sales order or project, and to process them.

Using this report, you can convert planned orders into production orders or purchase requisitions with the order structure in front of you.

This procedure is particularly suited to make-to-order production. Refer also to the Information Systems unit .


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APO as a Planning Tool

APO APO

Global ATP

Global ATP

DistributionDistribution

SAP BW

Historicaldata

Keyfigures

ExternalData

(for example,ITEM)

SAP BW

Historicaldata

Keyfigures

ExternalData

(for example,ITEM)

Demand planningDemand planning

Productionplanning anddetailedscheduling

SupplyNetworkPlanning

SupplyNetworkPlanning

Supply Chain CockpitR/3R/3

Sales anddistribution(sales orders)

Shop floor control

(prod. orders)

Inventorymanagement

Instead of R/3 requirements planning (MRP), you can use the new SAP product: Advanced Plannerand Optimizer (APO) . This product is one of the SAP New Dimension products.

APO enables a general, comprehensive portrayal, planning and monitoring of all processes in thelogistics chain, right down to a detailed level .

Open standard interfaces permit seamless integration of SAP Systems (highly-integrated solution forR/3), old systems and systems from external providers.

LiveCache , an SAP technology for processing data in the memory , gives APO its high performancelevel.

APO is an absolute planning machine . Inventory management, sales order creation and order execution and control (Manufacturing Execution)

are carried out outside of APO, for example in the R/3 System. Orders (planned, production or process) can be created and changed as the result of planning with APO. APO and R/3 are connected by the APO Core Interface (CIF) Data is kept consistent on both sides (APO and R/3). Planning with APO is dealt with in detail in courses AP010 to AP230 .


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Order Creation/Order Change Exercises

Unit: Order Creation /Order Change

Topic: Creating an order without basic data(LO215 Exercise 2)

Learn about the dialog for creating and changing a productionorder.

As production manager, production scheduler or supervisor, fromtime to time you must create production orders for which there isno master data (routing, BOM).This is particularly the case if production has to carry outunplanned work, special requests and other tasks.In this exercise, you will become familiar with the dialog forcreating or changing a production order.

1-1 Create an order using the following data:

Material T-MAN

Production plant 1000 Order type PP01

Total amount 10 piece

Basic finish date Any

Scheduling type Backwards

Path: S000 LO PP SFC ORDER CREATE

WITH MATERIAL

A dialog box appears: Routing Selection T-MAN

React to the system message: "No routing found" with

GENERATE OPERATION


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Machine time 10 pieces per 30 mins

Labor time 10 pieces per 60 mins

Path: S000 LO PP SFC ORDER CHANGE

1-6 Add material components "T-T1##" and "T-T2##" to operation "0010" in any quantity .

Use item category "L" for both.

Path: Go to the operation overview and select

operation "0010". In the menu bar at the bottom of the screen, select the COMPONENTS pushbutton

1-7 To operation "0020" , add the production resource/tool "PP-FHMM" . with anyquantity .

Path: Go to the operation overview and select

operation "0020".

In the menu bar at the bottom of the screen, select the PRT pushbutton

(production resources/tools)

A dialog box appears: PRT New Entries

Note that this production/resource tool has a materialmaster .

The window is set up accordingly. If you want to add otherPRT categories, you must select the pushbutton at the

bottom.

1-8 Execute a document link, by linking the order with document T-D##.

Document no. T-D##

Document type DRW

Subdocument 000


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Document version 00

Assign the document to operation 0010 .

Path: Go to the document overviewGOTO OVERVIEWS DOCUMENTS

1 -9 Check the operation overview.

1-10 Carry out order costing (determine costs).

Path: FUNCTIONS COST

1-11 Display the costing result.

Path: GOTO -> COSTS -> ITEMIZATION

1-12 Save the order.

Path: ORDER SAVE


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Order Creation/Order Change Exercises

Unit: Order Creation /

Order ChangeTopic: Creating an Order with Basic Data

(LO215 Exercise 3)

Routing and BOM selection

Production versions in a production order

Reading master data

As production manager, production scheduler or supervisor, as arule, you create production orders on the basis of master data(routings, BOMs), which has been created and is maintained inthe areas of engineering and work scheduling in your company.This is particularly the case when the production of materials andactivities is of a repetitive nature.In this exercise you become acquainted with the way in which theSAP System searches for and selects the master data that is validfor a production order.

2-1 Create an order using the following data:

Material T-F1##

Production plant 1000

Order type PP01

Total amount 1 piece

Basic finish date Any

Scheduling type Backwards

Path: S000 LO PP SHOP FLOOR CONTROL ORDERCREATE WITH MATERIAL

2-2 What is the validity date of the BOM and the routing in the production order?


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