production planning for process industries-ecc6.0-ver1
TRANSCRIPT
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SAPProduction Planning for
Process Industries
(PP-PI)Configuration Pack
Published by Team of SAP
Consultants at SAPTOPJOBS
Visit us at www.sap-topjobs.com
Copyright 2008-10@SAPTOPJOBS
All rights reserved. No part of this publication may be reproduced, stored in a
retrieval system, or transmitted in any form, or by any means electronic or
mechanical including photocopying, recording or any information storage and
retrieval system without permission in writing from SAPTOPJOBS
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INDEX
1. PRODUCTION PLANNING - PROCESS INDUSTRIES (PP-PI) 3
2. DEFINE PROFILE WITH DEFAULT VALUES 5
3. ASSIGN MATERIAL TYPES 10
4. DEFINE RECIPE STATUS 13
5. DEFINE RECIPE USAGE 16
6. DEFINE PRIORITY SEQUENCE FOR AUTO RECIPE SELECTION 19
7. DEFINE ORDER TYPES 22
8. DEFINE ORDER TYPE DEPENDENT PARAMETER 26
9. DEFINE NUMBER RANGE 36
10. DEFINE CONFIRMATION PROFILE 39
11. PROCESS MANAGEMENT 47
12. TRANSPORT PREDEFINED CHARACTERISTICS 50
13. TRANSPORT PREDEFINED MESSAGE CATEGORIES 52
14. DEFINE AND SETUP CONTROL RECIPE DESTINATION 57
15. DEFINE PROCESS MESSAGE CHARACTERISTICS 64
16. DEFINE AND SETUP MESSAGE DESTINATIONS 69
17. DEFINE AND SETUP PROCESS MESSAGE CATEGORIES 72
18. PROCESS INSTRUCTION CATEGORY 78
19. SUMMARY:- 86
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1. Production Planning - Process Industries (PP-PI)
PP-PI is used in process industries where there areinstructions and activities are to be confirmed during theprocess.
PP-PI using process orders without process Instruction andcontrol recipe also used in many places where there is no needto get confirmation of intermediate activities performed alongthe process.
If the process is long and there are many actions to be
confirmed during the process, it is achieved through thecontrol recipe and process Instructions.
Following are the steps involved to explain PI in a simple term.
•
In the Master Recipe, Process Instructions areattached to the phase.
• While creating the process orders, control recipe will
be created, which will contain the processInstructions.
• Control recipe will be sent to the proper destinationor to the operator who has to input the data toconfirm his action performed.
• Control recipe will be sent back to the process orderand instructions with data will be available.
Master Data in PP-PI:-
Bill Of Material:-
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List of components along with the required quantity tomanufacture a product.
Resource:-
Machine and process equipments are termed as Resource. Indiscrete it is known as Work center.
Master Recipe:-
Task list specifying the sequence of operations and itsduration is termed as Master Recipe. In discrete it is known asRouting.
Master Recipe contains:-
Sequences of operations are detailed in operation andphases. Each operation has to have at least one phase.
Duration for each processing is maintained in the phase.
Production version to be used in the master recipe
There are more terminologies about Process Messages andcontrol recipe, which are explained in the chapter 9.
Configuration explained here are the only extra configurationsettings to be performed for PP-PI.
Balance configurations explained for the DiscreteManufacturing process are same applicable to PP-PI also.
Few Example: - Configuration of BOM item category, Workcenter field selection, BOM selection.
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2. Define Profi le with Default Values
BACKGROUND:-
Default values to be displayed while creating Master Recipeare maintained in Profile.
In a profile you can specify default values for the followingareas:
•
General recipe data such as control keys and theincrement between
• Operation numbers
• Recipe graphics
• Quality data
When creating or changing a master recipe, you have to entera profile. The values of this profile are then offered as defaultvalues in the new recipe or the new recipe objects. You caneither accept or overwrite these values.
SCENARIO:-
Standard profile will be sufficient. Discuss the standardProfile.
MENU PATH:-
IMG Production Planning for Process Industries MasterData Master Recipe Settings for the task list type Define profiles with default values
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Click
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Click
Click
Click
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Field name Explanation for field
Control Key Default control key to appearin the master recipe
Operation increment Incremental number for eachoperation.
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Field Key Any user defined field key toappear in the operation
PI Increment Process Instruction incrementcount
PIC increment Process InstructionCharacteristic increment
To create new entries,
Click
Maintain the above explained data.
Click
Note: - Profile is a mandatory entry while creating MasterRecipe.
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3. Assign Material Types
BACKGROUND:-
Only materials of the material types allocated in this step canbe allocated to a master recipe at the header level, that is, asthe material to be produced.
SCENARIO:-
Discuss the material type assignment setting.
MENU PATH:-
IMG Production Planning for Process Industries MasterData Master Recipe Settings for the task list type Assign Material types
Click
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Click
Maintain Task List type. E.g. 2 to indicate Master Recipe
Maintain Material type. E.g. FERT to indicate Finished goods.
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Click
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4. Define Recipe status
BACKGROUND:-
The recipe status determines:
• Whether a recipe is released for use in process orders
• Whether a recipe is released for costing
• Whether a consistency check is carried out before therecipe is posted
When a master recipe is created, a status must be assigned toit. This status can later be changed according to theprocessing stage of the recipe.
Together with the recipe usage, the recipe status is used tocreate priority sequences that serve as a basis for theautomatic selection of recipes during order creation, capacityplanning and costing.
SCENARIO:-
Define / Discuss the Recipe status.
MENU PATH:-
IMG Production Planning for Process Industries Master
Data Master Recipe Data for the Recipe Header DefineRecipe status
Click
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Field Name Description and Value
Status Number identifying the statusof the master recipe
Description Description to the statuscreated
Rellnd Indicates Release status of therecipe. If the recipe is not
released, it can not be used tocreate process order.
Cstng Indicates relevancy to costing.Status number with thischeck box will be consideredduring costing run.
Cons.chk. Indicates to carryout theconsistency checkautomatically while saving.
To create new status,
Click
Maintain the data as explained above
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Click
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5. Define Recipe usage
BACKGROUND:-
The recipe usage determines:
• The purpose or area, for which a recipe is created
example, the chemical, the pharmaceutical or the foodindustry
When you create a master recipe, you must assign a recipeusage to it.
You can create several recipes with different recipe usages forone material.
SCENARIO:-
Create Recipe usage
MENU PATH:-
IMG Production Planning for Process Industries MasterData Master Recipe Data for the Recipe Header DefineRecipe usage
Click
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Click
Field name Field description and value
Usage Number identifying the usage.E.g. 1
Description Description of the usage. E.g.Production indicates thisusage is for process order
creation.
DCr Dynamic Modification Criteriato change the inspection scopedynamically if required.001 – for material base tochange the inspection scope.
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002 for material and customercombination to change theinspection scope.003 for material and vendor
combination to change theinspection scope.
Optional entry can be leftblank if no DynamicModification Criteria isrequired.
Click
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6. Define Priority sequence for Auto RecipeSelection
BACKGROUND:-
Priority sequences are defined according to which masterrecipes are selected in the following cases:
•
for order creation
•
for costing
Each priority sequence is identified by a selection ID.
The selection criteria are:
• task list type (2 for master recipe)
• task list (recipe) usage
•
task list (recipe) status
Priority sequence will be determined within a selection ID bydefining selection priorities for different value combinations ofthese selection criteria.
During the automatic selection of recipes, the system choosesthe recipe with the highest priority.
Use
The selection of recipes is carried out automatically
• if you have not maintained a production version and
•
if you have entered a corresponding key for theparameter "Master recipe selection" in the order type
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Field name Field description and Value
ID Selection id number. E.g. 04
Selection priority. E.g. 1 toindicate first priority in the idgroup 04.
Task list type. E.g. 2 toindicate Master recipe
Usage. E.g. 1 to indicate therecipe usage number 1 to bepicked up.
Status of the recipe to be
picked up. E.g. 4 will firstpickup the recipe with statusnumber 4 i.e. Released statusas first priority
Above settings are for selection id 04 with selection priority 1.Similarly maintain rest of the selection priority 2,3 and 4 asshown above in the screen.
Click
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7. Define Order types
BACKGROUND
An order type covers control information that is required formanaging orders. Order type must be assigned to each order.
The order type defines the following:
• Order category
•
CO (Controlling) Partner update
• Order classification
• Open item management
•
Settlement profile
•
Retention period of the order
• Number assignment
•
Status management
SCENARIO:-
Define / Discuss an Order type
MENU PATH:-
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IMG Production Planning for Process Industries ProcessOrder Master Data Order Define Order Types
Click
To create new entries, it is suggested to copy from the SAPstandard order type PI01.
Select PI01
Click
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Field name Field description and value
Order category Internally defined field withpredefined value as 40.
Order type Field referring the order type.E.g. YA70 to define your ownorder type
Description Description to the order type.E.g. Process order (internal
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number)-IND6
Leave the rest of the fields with the existing entries.
Click
Click
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8. Define order type dependent parameter
BACKGROUND:-
Parameters that are valid for each order type and plant aredefined here. The parameters are split up as follows:
• Master data
Here, you define the data that influences master dataselection or order master data maintenance.
The screen contains the following indicators:
• Master Recipe Selection
•
Recipe selection ID
•
Application defines how the BOM alternatives areselected.
•
Cost accounting
Here, you define the parameters relevant for costaccounting, such as costing variants for planned andactual costs and a results analysis key.
• General data
Here, you define the following parameters:
Substitute MRP controller/substitute productionscheduler. These are proposed when you create processorders if an MRP controller or production scheduler isnot specified in the material master.
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CopyPlannedOrdSchedg - defines that scheduling of theplanned order is transferred unchanged to the processorder.
SCENARIO:-
Create an order type dependent parameter in Plant IND6 fororder type YA70
MENU PATH:-
IMG Production Planning for Process Industries ProcessOrder Master Data Order Define Order Type-Dependent parameters
Click
It is always suggested to create new one by copying fromstandard sap settings.
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Field Name Field description and Value
Plant Key identifying the plant.E.g. IND6
Order type Key identifying the order typealready created.E.g. YA70.
Production Version Selection of production duringprocess order creation.
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E.g. Select Automaticselection of productionversion.
Tick in this check box will
check the components whenexploding the Bill Of Material.Leave this blank.
Indicator specifying that anorder of this order typerequires approval.If you have set this indicator,the entire order or parts of itcan only be released if theorder has status Approvalgranted. Leave it blank.
Operation screen will bechecked when transferring thedata from Master recipe intothe order. Tick this check box.
Recipe selection Specifies whether a masterrecipe is selected when youcreate a process order and
how it is selected. E.g SelectMaster recipe proposedManual selection.
Selection ID Key which specifies thepriorities according to which,master recipe will be selected.
When you create the orders,they are automaticallyassigned status Order
record required. This status isdeleted when you archive theorder record. Only then can you archive and delete theorders.
If the entry tool is on,
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system automaticallybranches to the operation'sdetail screen after youcreate an operation in the
routing.Increment for each operation.E.g. 0010 will makeincremental order of 10.
Click tab screen
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Key indicates when to createthe reservation to thecomponents.E.g. 3 will create thereservation to the component
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as soon as the order iscreated.
Key identifies the right BOMapplication.
E.g. Process manufacturingwill ensure selection of PI01.
Click
Maintain the entry as shown above screen.
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Contents are same as to that of Production order type entries.Hence it is not repeated here.
Click
Below displayed is the controlling tab screen detail.
Entries here (costing variant planned and actual, resultsanalysis key and default rule) are maintained in discussion
with Controlling Module.
Click
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Maintain the entry as shown above. This is mainly to displaythe information in the reports of missing parts list.
Click
Note: - You will get a message No1 entry copied.
Click
Click
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9. Define Number Range
BACKGROUND:-
Each order is uniquely identified by an order number withinone client.
You allocate each order to a number range group via the ordertype. You can allocate several order types to the same numberrange and thus the same interval.
There are two types of number assignment:
•
Internal number assignment
When you create an order, the SAP System automaticallyassigns a consecutive number from the number rangethat you have defined.
•
External number assignment
When you create an order, you must specify a numberfrom the allowed number range.
SCENARIO:-
Define Number range for order type YA70
MENU PATH:-
IMG Production Planning for Process Industries ProcessOrder Master Data Order Number Ranges DefineNumber Range for Orders
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Click
To display the number range assignment Click
To maintain the number range assignment click
Note:- Since the new order type has been created throughcopying from standard sap order type, automatically numberrange has been assigned.
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If the order type has not been assigned with the numberrange, it will appear at the bottom.
Click
To select and assign the number range
Go to below in the screen where list of Not Assigned order willbe displayed
Click on the order type
Click select element
Tick the check box where it is to be assigned. E.g. as shownbelow
Click
Click
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10. Define Confirmation profile
BACKGROUND:-
This confiugration setting enables to define the confirmationprofile for single screen entry.
Confirmation profile is used in transaction COR6N forperforming confirmation.
Process order confirmation can be performed using COR6Ntransaction. This transaction similar to CO11N has the abilitydefine the tab fields to be displayed to the user by which moreoption can be exercised.
In order to use this, it is required to understand theconfirmation profile configuration.
SCENARIO:-
Define Confirmation profile.
MENU PATH:-
IMG Production Planning for Process Industries ProcessOrder Operations Confirmation Single entry Screen Define Single Screen Entry
Click
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Click
Maintain the entry as shown below
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Note:- click at
the to view how the header to look.
After selecting, click to view it
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Click
Similarly it can be done in the detail area also
Right side maintain the desired text for each area
Note:- Tick at the closed check box indicates that by defaultthis tab screen is closed. User has to open if required.
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Click
Click
Click
Click
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Click the desired profile as Standard profile.
Click
Click
Impact of this configuration in Master Data /Transaction
While performing the confirmation using COR6N, screen willappear as per the setting maintained here.
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11. Process Management
Friends,
Configurations similar to that of discrete production processare
BOM Selection
Task List selection
Availability check
Scheduling
Confirmation parameter
Now the next important settings related to PP-PI are theprocess instructions and process messages.
Before we go ahead, let’s discuss some of the important
terminologies and definitions related to Process Instructionsand process messages.
Control Recipe Destination:-
The control recipe destination specifies
•
The technical address to which a control recipe istransferred
• How the transfer takes place (for example, initiated byR/3 or by process control)
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Process Instruction Characteristics:-
A characteristic of a characteristics group released for use inprocess instructions.
Process instruction characteristics are allocated to processinstructions either directly or via the instruction category.
Together with the corresponding characteristic values, theydetermine:
•
The information transferred or requested in a processinstruction (for example, the status of a control recipe)
•
How the requested data is to be processed (for example,the message category to be used to report the data)
Process Message Characteristics:-
A characteristic in a characteristic group which has beenreleased for use in process messages. Process messagecharacteristics are allocated to process message categories.
Together with the corresponding characteristic values, theydetermine the content of a process message.
Process Message Categories:-
The process message category specifies:
•
The characteristics to be allocated to a process message,i.e. the information to be sent
• The message destinations to which a process message isto be sent.
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Process Instruction categories:-
The process instruction category specifies:
•
the type of process instruction (for example, processparameter or process data request)
•
the characteristics of this process instruction, that is, theinformation to be sent via this instruction
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12. Transport predefined Characteristics
BACKGROUND:-
In this step, transport the process instruction characteristicsand process message characteristics predefined by SAP fromthe SAP reference client to the logon client.
You need these characteristics
•
For the message categories predefined by SAP
• To create your own message and process instructioncategories
Note:-
The names of the characteristics predefined by SAP all startwith PPPI_.
You cannot change these characteristics in your logon client.
After carrying out this step, the standard characteristics areavailable in all Plants in the client.
When you import these characteristics, the system will issue aWarning which informs you that this data is of type "A".Ignore this message.
SCENARIO:-
Copy the characteristics to the new client.
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MENU PATH:-
IMG Production Planning for Process Industries ProcessManagement Standard Settings Transport Predefined
Characteristics
Click
Message will be displayed as shown above in the system afterperforming this task.
Click
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13. Transport Predefined Message Categories
BACKGROUND:-
Predefined (by SAP) message categories will be copied to therequired new client In this step as Customizing settings.
These message categories are required for:
• The link to PP, MM and QM
•
The link to higher-level systems (linking of externalrequirements)
•
status management in the case of orders and controlrecipes
The predefined message categories are copied together with alltheir assignments (assignments of characteristics, estinationsand destination-specific target fields).
Note:-
First characteristics for process management predefined bySAP have to be copied before performing this step.
SCENARIO:-
Copy the standard Process message categories (created bySAP) to the new client.
MENU PATH:-
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Click to copy
Click
Click
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Click
Click
Click to display the list of message categories
Click to copy
Click
Click
Note:-
This above settings of copying the standard settings created bySAP will be sufficient to work with process instructions.
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14. Define and setup control recipe destination
BACKGROUND:-
This configuration setting enables to define the control recipedestination.
A control recipe destination defines the following:
• Whether the process instruction of a phase is transferredto an external system or is converted into an R/3 PI sheetfor a line operator
• Which system or line operator processes the processinstructions of a phase
An operation can contain many phases.
Each phase can have different control recipe destination.
In the process order, one control recipe can be created for eachcontrol recipe destination.
Make the following settings for the control recipe destinations you want to use in your plant:
• Define the control recipe destinations as below.
- Information on the type of signature used in PI sheets (forexample, signature with password check or digitalsignature)
- Data that controls system performance during PI sheetdisplay
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Enter Plant. E.g IND6
Click
Click to create new entries. Standard setting shouldbe sufficient.
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Field Name Field description and Value
Plant Enter plant code. E.g. IND6
Ctrol Rec.Destin. Code identifying the controlrecipe destination. E.g. 06
Description of control recipeDestination
Enter the control recipedescription. E.g. PI Sheet.
Destination Type Destination for processInstructions to be sent viacontrol recipe. E.g 1 indicatesthe Control recipe transfer toR3 PI sheet.
Address Name or group of line operatorwho maintains the PI sheet.E.g. Group 1.
Click
Click
Click
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Select 01 destination by clicking left side grey box
Double click in the left side of thescreen.
Click . Maintain the entry if it is required to defaultcertain process instruction other wise leave it blank. It can bemaintained at recipe level.
Screen without any Process instruction for your reference: -
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Field name Field description and value
Position PI position in the controlrecipe to be maintained. 01refers to at the start of thecontrol recipe and 05 refers toat the start of the phase.
Sequence Number defining thesequence.
Instruction category Instruction category to which
PI are to be generated.
Click
Click
Lick
Note:-
Process Instructions will be determined from the InstructionCategory. No need to assign the PI to the destination type 01.
However Process Instructions to be generated will define theposition of PI in the control recipe.
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It is only optional entry. Process Instructions can be definedinside the master recipe also.
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15. Define Process Message Characteristics
BACKGROUND:-
Process message characteristics in addition to the existingcreated by SAP, can be created if required.
SCENARIO:-
Create Process message characteristics
MENU PATH:-
IMG Production Planning for Process Industries ProcessManagement Process Messages Process MessageCharacteristics Define characteristics for Process Message
Click
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Double Click
Enter the characteristic name as LOT_QUANTITY
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Status
Data TypeNumber of digit incase of numeric data
Click
Click
Additional information
Automatic value assignment
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Maintain the data if automatic value is to be assigned.
Table 01 will refer the Process order header. Press F4 toDisplay more choices
Field Select the desire field. E.g GAMNG refers to orderquantity.
Will ensure automatic assignment of value
Click
Click
Note:- Most of the standard Process message characteristicscan be used to meet the requirements. New characteristics canbe created as explained above.
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16. Define and Setup Message Destinations
BACKGROUND:-
Define the following setting for the message destinations:
•
Define the message destinations with their addresses.
Message destinations are defined per plant.
Assign destinations to messages via the message categoryor directly in the process message.
SCENARIO:-
Define and setup Message Destinations
MENU PATH:-
IMG Production Planning for Process Industries ProcessManagement Process Messages Process MessageDestinations Define and Setup Message Destinations
Click
Enter Plant E.g IND6
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Click
By default required standard settings will be available.
Field Name Field description and Value
Destination Key identifying destination
Description Description of the destination
Type Destination type. E.g 01
indicates the R3 Functionmodule
Destination address Name of the function moduleto be called.
Note:-
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Below are the example of SAP standard function module anddefinitions.
Function module
COCI_CONFIRM_ACTIVITYConfirmation of activities
COCI_CONFIRM_MATERIAL_CONSPosting of goods issues
COCI_CONFIRM_MATERIAL_MOVEMENTPosting of general goods movements
COCI_CONFIRM_MATERIAL_PRODPosting of goods receipts
COCI_CONFIRM_OPERATIONConfirmation of processing time events
COCI_CONFIRM_TIMETICKETConfirmation of time ticket
Click
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17. Define and Setup Process Message Categories
BACKGROUND:-
Every process message that you want to send via processmanagement must be assigned to a process instructioncategory.
In this section, define the message categories that you want touse in your plant.
For each message category, specify
•
the information to be contained in messages of thecategory (via characteristic assignments)
•
the destination to which the messages should be sent
• the destination fields to which the values of theindividual message characteristics should be transferred
SCENARIO:-
Define and setup process Message categories
MENU PATH:-
IMG Production Planning for Process Industries ProcessManagement Process Messages Define and SetupMessage Categories
Click
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Enter Plant. E.g IND6
Click
Note:-
Above displayed message categories are assigned to plantIND6
Let’s look Characteristics for PI_CONS message category
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Select PI_CONS by pressing left grey box
Double Click in the left side of thescreen
Above shown characteristics are attached to the messagecategory PI_ CONS
Let’s look at the destinations to the PPPI_BATCH
Select PPPI_BATCH by clicking the left grey box
Double click
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To the message categories there are many messagecharacteristics were attached. Now there are only selected
characteristics attached specific to the destination.
Let’s look at the characteristics attached to the PI01 and to thePI04 destination.
Select PI01 by clicking grey box in the left
Double click in the left side ofthe screen
Important Note:-
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Though there are many message characteristics attached tothe message category, to the destination PI01onlyPPPI_PROCESS_ORDER characteristic is attached
Click
Similarly repeat for PI04
Click till you reach the main IMG screen
We have discussed
Control recipe destination definition
Message characteristics
Message Destinations
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Message categories
Now let’s discuss Process Instruction characteristics.
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Click
Field Name Field description and Value
Instr Cat Key identifying the instructioncategory. E.g ACONS_1
Description Description identifying theinstruction category
ProcessInstr.Type*** Number identifying theinstruction type.
*** Instruction type describes the type of process Instruction
1-- Refers to Process Parameter
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It is used in PI Instruction to attach some notes, any textdetails through Long text
2 – Refers to Process Data Request
It is used whenever there is a need to get the data asinput
3 – Message subscription
A process instruction that specifies that processcontrol is to send a message every time a specificevent, for example, a goods receipt, occurs.
4 – Process Data calculation formula
A type of process instruction that specifies that avalue must be calculated in the PI sheet. This value isthen sent to a particular destination using a processmessage.
5 – Inspection Result Request
The inspection results request specifies the operationsand phases for which inspection results must berecorded. For these operations and phases, the functionfor recording inspection results can be accesseddirectly from within the PI sheet.
6 – Dynamic Function Call
Process instruction which enables the line operator tocall a user-defined function module from within the PIsheet.
Depending on the function module, this option can beused to access order confirmation or material quantitycalculation or to start a user defined function module.
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7 – Sequence Definition
It is used to define the PI sheet entry sequence
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Let’s try to look at the list of characteristics assigned to theprocess Instruction category ACONS_1
Select ACONS_1 by clicking the grey box in the left
Double click in the left side ofthe screen
Here any newly created characteristics can also be attached ifrequired.
Note:-
Field Name Field description and Value
No Serial number forcharacteristics
Characteristics*** Process InstructionCharacteristics. Here we haveto mention the PIcharacteristics predefined by
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Select CONS_1
Double click in the left side ofthe screen
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Note:-
First characteristic is PPPI_DATA_REQUEST_TYPE which willdiver to the goods issue module. Always first characteristic
should be the one which takes to the right module.
In the above,
PPPI_REQUESTED_VALUE is assigned to get the quantityof material consumed. Whenever it is required to get theinput this characteristic is to be used.
Click
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19. Summary:-
Guys, I am sure, you are now equipped to configure the SAP
PP-PI production process with process messages according tothe business blue print with this configuration manual.
Wish you all the best.