Production Planning

Work Centers for Fitter Snacker

Raw Material Warehouse (100) Mixer Snack Bar Line Mixer Form Mixer Production (200) Mixer Bake Pack Finished Goods Warehouse (300)

Production Master Data

Company Code Valuation Area

Work Center Material Master

Routing

Capacity Planning
Production Orders

Plant

Bill of Material

Product Costing

Navigating Material Master Views

Click on tabs to select Use direction arrows to scroll Use icon to get list

Material Types
A Material Type is used to classify materials: Defines material attributes like: Valuation (value of material as market changes) Procurement (internal, external or both) Controls screen sequence and number assignment Can restrict access using authorization groups A number of material types are pre-defined Abbreviations are abbreviations of German terms Users can create their own material types Usually best to copy a pre-defined type, then modify

Material Types in Exercises

ROH: Raw material Externally purchased only, no sales view Oats, Wheat Germ, Honey, Cinnamon, etc. HALB: Semifinished Product No purchase or sales view Dough for NRG-A and NRG-B bars FERT: Finished Product Produced internally, has sales views, no purchasing views NRG-A and NRG-B bars

Other Material Types

HAWA: HIBE: VERP: LEER: KMAT: ERSA: DIEN: NLAG: UNBW: FHMI: WETT: PROD: IBAU: Trading Goods Operating Supplies Customer returnable packaging Empty containers Configurable material Spare parts Services Non-stock, non-valuated material Non-valuated, stocked material Production resources/tools Competitive products Product group Maintenance assembly

Documentation in Material Master

The SAP R/3 system documents all changes to the material master:

Click for documentation

Documentation in Material Master

Master Data Bill of Material

BOMs are represented as single-level relationships between a material and its components and sub-assemblies
## NRGA (case)

BOM for NRG-A

## Dough NRGA (lb)

BOM for Dough NRG-A

## Oats (lb)

## Wheat Germ (lb)

## Cinnamon (lb)

## Nutmeg (lb)

## Cloves (lb)

## Canola (gal)

## Honey (gal)

## Carob Chips (lb)

## Raisins (lb)

## Vit/Min Powder (lb)

Routings
Routings define the relationship between a material and the sequence of workcenters (operations) that are required to produce the material Also specifies where sub-components and sub-assemblies are needed in producing the material
10 20 30 40 50 60

Functions of Production Orders (part 1 of 2)

Status Management: Tracking, User-defined status Scheduling Calculation of Capacity Requirements (detailed) Costing/Collection of Costs Availability Checks (material, capacity, PRTproduction resources and tools) Printing of Paper Orders/related documents Assembly drawings and instructions Inspection instructions Storage regulations Material Staging: withdrawal of materials used in production, e.g. components and sub-assemblies

Functions of Production Orders (part 2 of 2)

Confirmations: quantities, activities, times Goods receipt: receipt of completed materials Period-end closing: Process cost allocation, overhead costs, surcharges, WIP (work-in-process) calculation, variance calculation, order settlement Archiving and retrieval Many more: rework, serial numbers, as-built, quality control, etc.

Production Orders capture actual data costs, dates, etc.

Status Management (part 1 of 2)

Status Management is one tool that can be used to manage released production orders A status can allow, allow with warning, or block a business transaction Two status types are available System status: internal, predefined, fixed number User status: freely definable, set by user

Status Management (part 1 of 2)

Status

Status detail

Planned Orders vs. Production Orders

Planned Orders are for PLANNING Production Orders are for EXECUTION
Planned Order 3 weeks in future

Planned Orders 2 weeks in future

Planned Orders 1 week in future

Planning Execution

Production Orders released today

Master Data for Production Orders

Master Data is data that does not change frequently Master Data for the production order comes from: Material Master Bill of Material (BOM) Work Center Routing Production Resources/Tools (PRT) Materials like gages, fixtures, test equipment Can also be items like drill bits that can be consumed in production but arent consumed INTO the product Most Production Order data comes from BOM and Routing

Archiving & Deletion Order settlement

15

Order Request
16
1 2 3

Order Creation

Availability Checks
4

Variance Calculation

14

Goods Receipt WIP Determination

13

Production Order Cycle

11 7 10 8

Machine Reservation Order Release

5 6

12

Download to PDC system

Confirmation
Upload from PDC system

Print Order
Material staging

Material withdrawal posting

Routing Selection
Different routings can be selected for a product depending on a number of criteria like: Raw material used Lot size Product features/configurations (variants) A complicated, automatic selection process can be configured

Bill of Material (BOM)

The system selects the FIRST Valid BOM it finds Validity can depend on: Date (engineering changes) Customer Serial number

Material Assignment
Material
Material Material Assigned via BOM: All materials assigned to first operation

OP OP OP OP OP .. 0010 0020 0030 0080 0090

OP OP OP OP OP .. 0010 0020 0030 0080 0090

Material

Material

Assigned via Routing: Materials can be assigned to specific operations

Material