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2.1 2.2 2.3 2.4
OVER VIEW:DEFINE ORDER TYPE
Defining Order type and Order type dependent parameters Define Number Range for Orders Define status profile Define selection profile
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DEFINE PRODUCTION SCHEDULING PROFILE
Define production scheduler
4.1 4.2 4.3
Define Checking Rule Define Scope of check Define Checking control
DEFINE CHECKING GROUP
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5. 6. 7. 8. 9.
9.1 9.2 9.3
DEFINE SCHEDULING PARAMETER FOR PROD. ORDER DEFINE CONFIRMATION PARAMETERS DEFINE REASON FOR VARIANCE DEFINE DEFAULT VALUES REPETITIVE MANUFACTURING:Define Repetitive Manufacturing Profile Creating product cost collector Required Material Master Settings Rep. Mfg.:-
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85 91 95
PP CO INTEGRATION:Define Valuation of Goods Received
Define Valuation variant:Define Costing Variant
Over view:We have so far seen the Master data and production planning steps in PP. First let us understand what is happening in the system prior to the production execution process. Master data (BOM and Routing details) will be copied in to the planned order automatically during MRP run.1. a. Material Requirement Planning run will generate the planned order for the net required quantity with the start date of the production process c. Guys. Configuration settings related to Discrete Manufacturing and essential Repetitive manufacturing is discussed in detail here. . b. Planning quantities are derived and maintained in the system. Alright lets breeze through this. I believe you got an idea about the steps involved prior to the production execution process. In this document we will go thru the nuts and bolts of Production Execution. Ø Discrete Manufacturing Ø Repetitive Manufacturing Ø Production – Process Industries. There are three types of production process in SAP. let’s discuss about the production execution process now. OK.
Converting planned order to production order:Planned order has to be converted to production order to account the entire production. Releasing the production order:Release of production order is an important step in production order. While releasing the production order system can perform § Material availability . Production order or process order type has to be mentioned when converting the planned order. Entire master data will be copied to the respective order when converting the planned order. b. Releasing of production order indicates the commencement of production. Unless the order is released. They are Ø Converting planned order to production order Ø Releasing the production order Ø Goods Issue for production order Ø Confirmation of production order Ø Goods Receipt against production order a.Production Execution process contains five important steps. Order type is the most important configuration setting for production execution. further processing of order is not possible.
c. Confirmation to the each operation will be executed according to the control key attached with each operation. Goods issue can be made in parallel during confirmation of operation. order type parameters. the document number can be updated in the production order. Goods Issue for production order:Goods issue covers issuing required components to make the finished product to a production order. While making the goods issue. Confirmation configuration setting controls Adhering to the sequence of operation Under delivery / over delivery tolerance . Configuration setting related to this is discussed in order type parameter. Relevant configuration settings related to goods issue during confirmation are discussed in confirmation parameter. Confirmation of production order:Reporting of usage of components and activities are termed as confirmation.§ Capacity availability § Creation of Batch § Reservation creation Configuration settings related to the above functions are covered in Availability check. d.
Document number will be generated for each goods receipt. Hope the above briefing has given you the enough idea to go ahead for configuration of production execution process.Back-flush components Proposal and calculation of activity standard value Above configuration settings confirmation parameter. . Through confirmation 2. finished products will be received from the production order into the respective storage area. Goods Receipt against production order:Once the production is completed. are discussed in e. This can be achieved through two ways 1. Configuration settings related to these are discussed in Production scheduling profile and order type parameter. Through separate transaction. This document number can be updated in the production or process order. Now you will easily understand what is backflush? It is the process of issuing components automatically while confirming the production or process order.
SCENARIO Create order type YP01 for plant IND6 INSTRUCTIONS Follow the Menu Path: IMG à Productionà shop floor control à Master Data à Order à Define order types. one order type for regular production and another order type for rework processing. Define Order Type BACKGROUND This configuration setting enables to define order type. Click Click . There can be more than one order type for different production method. Order type governs the parameters relevant to controlling and defines what type of master data are to be picked up during the production or process order creation.2. E.g.
enter YP01 to refer the production order type. Enter the description. Leave it as it is. Key identifying the order type.g.Update the Following fields Field Order category Order type Description Description Order category defined by SAP. Basic production order type. E.g. . E.
g.Classification check box Resident time 1 and 2 Settlement profile Status profile Header Operation Status profile Tick mark in this check box will classify the production order internally. E.g. E. there should be one month gap between deletion indicator setting and deletion flag. Profile defining how the order is to be settled.g. Related to costing. It indicates.g. E. Click Click Impact of this configuration in Master Data / Transaction . Related to Archiving the object. E. enter 30 User created status profile applicable to this order type. Leave it blank Click Save . Enter 1 in Resident time 1 and in resident time 2. Leave it blank User created status profile for operation applicable to this order type.
Number range and controlling parameter (like settlement rule) are picked during creation of production or process order according to the configuration setting defined in the order type. .Order type is a mandatory entry while creating production or process order.
2. order type dependent parameters defines Selection of master data (BOM and Routing) Creation of Batch Updating the document numbers in the order Creation of reservation SCENARIO Define order type dependent parameter for Plant IND6 and order type YP01. When creating process or production order.1 Defining Order parameters BACKGROUND type and Order type dependent This configuration setting enables to define the order type dependent parameters. INSTRUCTIONS Follow the Menu Path: IMGàProductionà shop floor control à Master Data à Order à Define order type dependant parameter. Click .
Note: .It is suggested to create plant parameter by copying form the standard settings. Click . Select 1000 and PP01 line by clicking the grey box in the left.
.Press Pg Dn key in the key board to look at the balance portion of the screen.
E. 0 to select automatically.g. Indicating how the production version is to be selected while creating production order. IND6 Key identifying the order type. E. E. enter YP01 to refer the production order type. Enter 6 to indicate routing as Mandatory and automatic selection. Selection id number according to which routing will be selected. Enter 2 to indicate manual selection of sequence.g. Selection of sequence in the routing.g.g. E.g. Enter 01 Requirement and selection of routing. To indicate whether routing mandatory or not. E. Tick the check box to indicate Routing – Selection ID Routing Selection Sequence Exchange . Recollect the Creation of routing selection id creation. E.g.Update the Following fields Field Plant Order type Production version Description Plant to which this order type is applicable.
the alternate sequence can be copied into the order from routing.g.g. Enter PP01 Batch search procedure If required maintain the standard search procedure. Please refer for more detail. E. E. Task List type What type of task list this order type to pickup. Leave it blank.g. . E. E. E. Enter 3 to indicate immediately Tick this check box to raise purchase req. Tick this check box Routing Text Routing header text will be copied to the production order if this check box is ticked. collectively for all externally processed operations in an order. it will check all the entries. In the General tab screen below explained details are to be maintained Assignment of substitute MRP Leave it blank. controller and production scheduler Reservation Purchase To indicate when to generate requisition purchase requisition. Enter 0010 BOM Application Indicating which BOM is to be used to this order type.g.g. Tick this check box Operation increment Incremental to the operation. Routing. whether Reference operation set. E. E.g. Enter N to indicate Routing.g. Operation detail check check While transferring routing box operation to Production order.
.Click Field name Field description and value Tick in the check box will record the changes to the order at header level Tick in this check box will update the document details in the Logistic Information System which will help to view the document from the order header.
Can be left blank. enter as per CO module advise.g. as CO also can maintain through their module . Click Costing variant planned Costing variant is the one which contains valuation variant which indicate what price to pickup to calculate planned price calculation. E.Tick in the check box will create document for respective goods issue.
Enter as per CO module advice. Enter 2 to calculate planned cost while saving. to pickup the actual price calculation. Leave this check box blank. Related to CO to indicate how to distribute cost.g. as CO also can maintain through their module. Indicating when to calculate the planned cost of a production order.Costing variant actual Results Analysis key Planned cost calculation Distribution rule Same as above.g. Get the value from CO module. Enter PP1 Tick in this check box will not allow the change the net price when copying from Purchase Request to Purchase Order. Click .g. E. E. Can be left blank. E. E. Maintain the SAP Standard. E. Related to CO module.g.g.
. Note: . Leave it as it is with the SAP standard settings. goods movement details in the order).This tab screen controls the parameter related to display. Click Save .If required separate display profile can be created and attached to the order type to have a desired display of reports (missing part list.
. determining planned and actual cost parameter for any given order type and plant combination. Order type parameter governs Selection of routing and updating document for production order. system will perform according to the configuration setting done for a specific order type and plant combination settings.Impact of this configuration in Master Data / Transaction When creating the production order or process order. Order type is a mandatory entry while creating the production order.
INSTRUCTIONS Follow the Menu Path: IMGàProductionà shop floor control à Master Data à Order à Define number range for orders Click . SCENARIO Define Number Range for order type YP01. Internal number will be picked up from the number range defined and it will be assigned automatically at the time of saving the production or process order.2 Define Number Range for Orders BACKGROUND This configuration setting enables to define number range to the order type. For each production or process order a unique number has to be assigned.2.
to create the number range intervals to display the number range intervals to change the current number range status
Order type which is already assigned to one group is displayed. YP01 not appearing here as it is yet to be assigned. Click to reach bottom of this page
Click on the line YP01 Click Click check box of Click to assign
The number range assigned to order type YP01
Click Save Click
Impact of this configuration in Master Data / Transaction
While saving the production or process order, number will be assigned automatically to the order.
.If an order type does not have a number range assignment. abnormal termination of program will be displayed while saving the production or process order.
2. INSTRUCTIONS Follow the Menu Path: IMGàProductionà shop floor control à Master Data à Order à Define status profile Click . it is possible to carryout confirmation. confirmation of order should not be possible. Status profile along with the selection profile will be used to restrict the processing of transactions for particular status of the order. Define status profile to meet the above scenario. I. SCENARIO With the system status TECO.3 Define status profile BACKGROUND This configuration setting enables to define the status profile. It is to be restricted with the user defined status. when the status is TECO.e.
E. EN to indicate Englsh. No confirmation after TECO Maintain Language.g. . NOCONF Maintain Text.Click Maintain the status profile name. E.g.g. E.
Click Double click on Field name Field description and value .
only statuses with numbers 20 or higher may be activated. It can be any alphanumeric with four digits. Status B has status number 40 and the 'lowest status number' 20. If status A is active.Stat Status Short text Init. even if status A is currently active. E. This is used to assign the status in an order. only statuses with status numbers Highest . Maintain your own status Maintain the short description of the status.g. o Once status B was active for the object. Tick this check to indicate the status as initial status. E.. E. 1 Name of the status. Any status can be defined as a initial status. This is similar to the lowest number. Status A has status number 30 and the 'lowest status number' 10.g. Enter the sequence number for status.g. CRTD will be the initial status in this status profile. Status A has the status number 30 and the 'highest number' 50. St… Lowest Serial number. CRTD to indicate the status created. E.g.g. E.
50 or less can be activated. Click Click . . Continue the above process till you maintain all required status.
Select the objects as shown above Click Click Click in the status 3 to which status the further processing is to be restricted. .
Click Click Below is the list of object to which the control is to be imparted. Click to go to the next page . Other wise without saving you will not be able to select more than one radio button in a page. Click to go to the next page Note: .On selecting each radio button it has to be saved.restriction for further processing is to be done on with the status TECO.Note: .
. However. Next action Field description and value Transaction performed in SAP. Indicator specifying that the business transaction cannot be carried out if this status is active. Indicator which specifies that the business transaction can be carried out if this status is active. E. Indicator specifying that this status does not influence the corresponding business transaction. Indicator which specifies that the status is to be activated when this business transaction is carried out. the system issues a warning message during processing of the transaction.Field name Business transaction No Influence Permitted Warning Forbidd. Indicator which specifies that the business transaction may be carried out.g. Confirm order refers to the order confirmation process through transaction code CO15.
Click to go to the next page .
Click to go to the next page .
Click to go to the next page .
Click to go to the next page to look for more possible functions. Impact of this configuration in Master Data / Transaction Status profile with controls to further processing will be assigned with the selection profile. . Click Click till you reach the main configuration menu.
Selection profile contains the status profile which controls the business transaction. INSTRUCTIONS Follow the Menu Path: IMGàProductionà shop floor control à Master Data à Order à Define selection profile Click .2.4 Define selection profile BACKGROUND This configuration setting enables to define the selection profile. Selection profile will be assigned to the process order. SCENARIO Define selection profile. Selection profile defines when the user defined status is to be activated.
Double click Click . NOCONF Maintain selection profile description. Not to confirm in TECO status.Click Maintain selection profile.g. E.g. E.
Status Not Field description and value Indicates.status profile contains the object and the control for the further action for each status. Note:. Click Click till you reach the main configuration menu. Note:status name can be any. Indicates the status profile. we will enter NOCONF as status profile we have created above. . E. Indicates the status is active or not active to pick up the status profile. In this example.g.Field name check box under column user Status prof. whether the status is user defined status or the system status. Enter the status profile which was created by you. Enter the status on which the status profile is to be selected. we have defined the status as TECO hence this check box is ticked.
Use Transaction COR2 to change process order Click in the status line Note: . . goods receipt will not be able to perform.If the user status is applicable to the order type irrespective of material. further confirmation.Impact of this configuration in Master Data / Transaction Selection profile will be attached into the production or process order in the user status. If the user status TECO is activated in the order with this selection profile. goods issue. it can be assigned at the order type itself in the order type configuration as shown below. Required status can be activated by the user to activate the user status. Below screen shot shows the assignment of status profile and the user status in the process order.
.Assignment of user status at the order header level is shown below.
receipt or confirmation can be performed. NOCONF is assigned as a user status. . Status TECO Technically completed is selected. no more goods issue.Stat prof. Now.
SCENARIO Create production scheduling profile. Click Click . Production scheduling profile is the key attached to material master in work scheduling view. Define production scheduling profile BACKGROUND This configuration setting enables to define the production scheduling profile.3. INSTRUCTIONS Follow the Menu Path:.IMGàProduction à Shop floor control à Master data à Define production scheduling profile. Functions involved with production scheduler are ü Automatic release of production order while creating ü Automatic Goods Receipt for Production order while confirming ü Automatically assigning specific order type for material while converting from planned order to production order.
g.Update the Following fields Field Plant Description Specifying the plant name where the production scheduler is to be applicable. On Release – Execute Printing Printing of shop floor papers etc as per the settings will be printed automatically on relase. IND001 Description Description of the production scheduler profile. Tick this check . E.g.g.Release check order. E. E. Production order will be box released automatically if this is ticked. IND6 Production scheduler profile Key identifying the production scheduler profile. Production Scheduler for A Line Automatic actions:While creating the production On Creation . Tick this check box if it is be release automatically. E.g.g. E.
Apart from the above explained important setting.g. E.g. PP01 Click Save .Goods Receipt Order type – Make To Stock box. Release will happen automatically. Note: . E. Tick this check box Order type to be used for products which are make to stock. Tick in this check box will automatically make the GR document while confirming. . If different order types are to be used for different product. that can be mapped with different production scheduler. Then for those materials. other controls available here are • Creation of transfer order in WM Management • Creation of Batch automatically on release of order • Creation of Batch classification as mandatory Impact of this configuration in Master Data / Transaction Production scheduling profile defined here has to be attached to the material master Work scheduling view. while creating the production order.
Production scheduler can be assigned to the material master in the work scheduling view. INSTRUCTIONS Follow the Menu Path:.1 Define production scheduler BACKGROUND This configuration setting enables to define the production scheduler. Functions involved with this key are ü Automatic release of production order while creating ü Automatic Goods Receipt for Production order while confirming ü Automatically assigning order type for material while converting from planned order to production order.3. SCENARIO Create production scheduler and assign with production scheduling profile.IMGàProduction à Shop floor control à Master data à Define production scheduler. Click . Production scheduler is a text entry to map the production scheduler with production scheduling profile.
E. IND6 Key identifying the production scheduler.g. Impact of this configuration in Master Data / Transaction Production scheduler mapped with production scheduling profile has to be attached to material master Work scheduling view. . E.Click Update the Following fields Field Plant Production Scheduler Description Production scheduler profile Description Specifying the plant name where the production scheduler is to be applicable.g.g. Products Key identifying the production scheduler profile. Description identifying the production scheduler. E. ASG to denote scheduler for A segment products. E.g. Scheduler for A seg. IND001 Click Save .
Then for those materials. Release will happen automatically. while creating the production order. .
Checking group defines the checking method of availability during availability check. Click .4. INSTRUCTIONS Follow the Menu Path:. Availability check BACKGROUND Define checking group This configuration setting enables to define the checking group. SCENARIO Define checking group.IMGàProduction à Shop floor control à Operation à Availability Check à Define checking group. Checking group will be used along with the checking rule to carryout material availability checking.
E.g. E.g. Enter B to accumulate . E. This key will be maintained in the material master MRP2 view.g. Type of requirement system to generate during sales order processing. Enter ZY Description of the checking group. Individual requirement or collective requirement. Collective Require.Click Update the Following fields Field Availability Description Total Sales Description This key defines checking group.
Individual requirement or collective requirement.g. E. Leave it blank.g. Tick in this check box will allow multiple users to process availability check for one material at the same time. E. E.Total Delivery requirements Block QtRq requirement day wise. E.g. No check – check box Accumulation Response RelChkPlan . If ticked. Type of requirement system to generate during Delivery processing. no ATP checking will be done.g.g. Leave it blank Availability check to a material against Planned Independent Requirement. Enter B to accumulate requirement day wise. Leave this blank Indicating the system to take all planned receipt and committed issues while making a ATP check during sales order processing. E. Enter 1 to do the above explained function. E.g. To issue output when there is a shortage of material. Leave this check box blank as it will block the material for other users to access while performing the availability check.
Click Save . Impact of this configuration in Master Data / Transaction This checking group along with checking rule will perform checking of material availability considering receipts and issues. . This Checking group ZY has to be mentioned in the material master Availability field in MRP2 view.
IMGàProduction à Shop floor control à Operation à Availability Check à Define checking rule.It is sufficient to use the standard checking rule PP. Click checking group will determine the . Checking rule configuration is a simple text entry to be defined in the system. Checking rule with availability check. SCENARIO Define / Discuss checking rule.1 Define Checking Rule BACKGROUND This configuration setting enables to define the checking rule. INSTRUCTIONS Follow the Menu Path:. Note: .4.
E.g.Click (only to create new entries. PP Checking rule.g. Standard SAP checking rule PP will be used in most of the implementations) Update the Following fields Field Checking rule . E.ChR Description Description This key defines checking Rule. Impact of this configuration in Master Data / Transaction . Click Save . Enter PP Description of the checking rule.
In MRP related setting Dependant requirement availability this checking rule is referred. .This checking rule will be defined along with the checking group to perform the availability check.
IMGàProduction à Shop floor control à Operation à Availability Check à Define scope of check.4. reservation SCENARIO Define checking scope for the combination of ZP and PP. blocked stock Receipt elements:Purchase order. planned order. quality stock. Scope of checking defines the stock. receipt elements and the issue elements to be considered for availability checking. Issue Element: Sales order. . Purchase requisition. INSTRUCTIONS Follow the Menu Path:. Example:Stock: Stock in transfer.2 Define Scope of check BACKGROUND This configuration setting enables to define the scope of checking to the combination of checking group and checking rule. delivery.
Tick the check box as shown above to consider Safety stock. stock in transfer and quality inspection stock.g.Update the Following fields Field Description Stocks – Various heading with Tick those check boxes whose check box under Stock stocks are to be considered while Availability checking.g. E. E. Tick the check boxes as . Receipts/Issues Tick those check boxes whose receipt element and issue elements are to be considering while Availability checking.
it will confirm a date after the RLT.Check without RLT Receipt in the past. Note: . or only to consider future date or both. Click Save . . E.e.material master must contain Availability check as ZY in MRP 3 view. System will check without considering Replenishment Lead Time. if system not able to find any receipt or stock for a particular requirement. Tick this check box. if this check box is not ticked. Leave blank to indicate to consider receipt element of both past and in future. Impact of this configuration in Master Data / Transaction This checking control will be executed wile performing the Availability Check. I.g.g. To indicate whether to consider the receipt element with past date. shown above. E. RLT is the time taken from material master.
Checking control configuration is to execute the availability checking during production order or process order creation and release. SCENARIO Define checking control for IND6 plant and order type YP01. INSTRUCTIONS Follow the Menu Path:.IMGàProduction à Shop floor control à Operation à Availability Check à Define checking control. This is defined to the combination of plant and order type.3 Define Checking control BACKGROUND This configuration setting enables to define the checking control. Click Click .4.
Update the Following fields Field Plant Description Plant identifying the manufacturing facility where this ATP logic is to be .
E.Release Control to specify whether to allow release of production order or not if any shortage of material.availchek for capacity indicate not to carryout any availability check.g Leave it blank to indicate to check as per ATP. Check material availability Indicating the system whether when saving order to carryout ATP or not during saving production order after any changes. E.g. E. Check Box NO avail. E.g. IND6 Order type Production order type to which this availability check is to be applicable. No Chk for PRT and Tick these check boxes to No. Checking rule Mention the checking rule.g YP01 Business Function Whether to carryout ATP checking during production order creation or at the time of production order release. 3 to stop releasing.g. Tick this check box. Enter 1 to user to decide before release. 2 to indicate to carryout ATP checking during Release of production order.g. E. PP Type of comp check Whether to check as per ATP or with Planned Independent requirement. Mat. 2 to release without asking. E.check Indicating the system whether to carryout ATP or not. E.g.g. E. Leave this blank if ATP is to be carried out. . Tick in this check box will not carryout ATP.applicable.
Click Click Save . system follows as below Read the checking rule for the order type Read the availability to the material Read the checking control to the above combination Output given according to the checking control . Impact of this configuration in Master Data / Transaction Link between master data. configuration and transaction: Checking rule in the order type configuration is PP Availability check in the material master is ZP (MRP3 view) Checking control for the group ZP and PP is maintained When creating the production order or process order.
Define Scheduling Parameter for prod. Scheduling parameter is essential to schedule the production order according to the Task list data.5. I.e.IMGàProduction à Shop floor control à Operation à Schedulingà Define scheduling parameters for production orders Click . Order BACKGROUND This configuration setting enables to define the scheduling parameter for production or process order type. Scheduling data for specific order type defines • How to schedule production / process order • Whether to generate capacity requirements • How to adjust order dates while scheduling SCENARIO Define scheduling parameter for order type YP01 in plant IND6. to determine the start date and end date for the order and to the each operation. INSTRUCTIONS Follow the Menu Path:.
g. Backward scheduling. Therefore you cannot enter a selection ID. IND6 Order type Order type under the Plant IND6 to which this scheduling type is to be applicable. Select Adjust basic date or depend date to adjust order start date. Tick this check box.g.g.g. E. Automatic Scheduling check Tick this check box to indicate box scheduling to be automatic. E. E. E. Adjust dates Indicating how to adjust the dates of production order or dependant requirement when rescheduling. To indicate the system to calculate capacity requirement.Update the Following fields Field Plant Description Plant to which this setting is to be applicable. E. * to indicate applicable to all production scheduler in the plant IND6. Enter YP01 Production scheduler Production scheduler to which this setting is applicable. E. Also the scheduling indicator is set automatically. Generate capacity reqs. . Production orders and process orders are scheduled at a detailed planning level using the routing or the master recipe. Scheduling type Type of scheduling. Tick this check box.g.g.
Click Save . . If it is backward scheduling. it is required to enter only order finish date while creating the production or process order. Impact of this configuration in Master Data / Transaction This setting determines the scheduling type while creating the production order.
Define confirmation parameters BACKGROUND This configuration setting enables to define the confirmation parameter to the order type in specific plant. Through confirmation transaction. completion of production will be reported in the system. Confirmation parameter to each order type is essential to perform the confirmation. INSTRUCTIONS all component irrespective back-flush .6. Confirmation parameter defines • To propose partial confirmation. or full confirmation • To propose value of activity • To calculate the activity value according to the quantity change • Confirmation sequence is to be adhered to or not • To display indicator SCENARIO Define confirmation parameter for order type YP01 in Plant IND6.
Follow the Menu Path:.IMGàProduction à Shop floor control à Operation à Confirmationà Define Confirmation parameters Click Click Update the Following fields .
Field Plant Order type Operation sequence Under delivery Over delivery QM Result rec. how the system to behave when that confirmation by QC is not done. E. whether operation sequence is to be followed as per routing or not. YP01 While confirming. Operation contains the quality characteristics and if that operation has to be confirmed. Select as shown above. Select as above. Select as shown above Leave this blank if only the back-flush components are to be proposed during the confirmation. IND6 Enter the order type to which this setting is to be applicable. if the yield quantity is less than the tolerance limit maintained in the work scheduling view of material master how the system to behave. Description Enter plant name to which this setting is to be applicable. Select as above While confirming.g. . E. system will propose all the components assigned to an operation.g.g. While confirming. If this indicator is set. if the yield quantity is more than the tolerance limit maintained in the work scheduling view of material master how the system to behave. E.
g. E. system will give you a log message screen and request you to say yes or no to correct the errors occurred in Goods movement during confirmation.Click screen tab Field Confirm type Goods Movements Description Type of confirmation to be proposed during confirmation transaction. Leave it blank tab screen Click . Select as shown above If this check box is ticked. E.g. Tick in this check box will give the ERROR message incase of failure occurred during the goods movement.
When the yield quantity is changed from the default display.Update the Following fields Field Description To propose the quantity during confirmation transaction. all other activity and quantities are calculated with this tick in this check box. . according to the new yield quantity.
Impact of this configuration in Master Data / Transaction While confirming the production order. Over delivery tolerance 25 % maintained in the work scheduling view of material master While confirming.Make other ticks in the check boxes as shown above. . change the over delivery tolerance checking into an error message. Click Save . system will perform according to the setting maintained here. system will allow to continue the transaction. the confirmation quantity entered as 1500 (which is more than over delivery tolerance). As per the configuration setting here. Example:Production order quantity = 1000. If it is not to be allowed. as they are self explanatory.
7. Define Reason for Variance
BACKGROUND This configuration setting enables to define the variance reason. Variance can be mentioned during confirmation to indicate the reason for deviation from the standard. It is a simple text configuration. SCENARIO Create a variance key to specify “Machine malfunctioning”. INSTRUCTIONS Follow the Menu Path: IMGàProduction à Shop floor control à Operation à Confirmationà Define Reason for variances Click
Update the Following fields Field Plant Reason
Description Key identifying Plant. E.g IND6 Code identifying the reason.
E.g. Enter 0009 Description of the code. E.g. Machine malfunctioning.
Click Click Save .
Impact of this configuration in Master Data / Transaction
Codes maintained here can be selected during confirmation of production / process order to enter the reason for variance.
Default values are required to create the operation inside the production order or process order automatically if there is no task list. Default values are defined to a specific order type.8. IND6 . E. INSTRUCTIONS Follow the Menu Path: IMGàProductionàShop floor control àOperations à Task list selection à Define default values Click Enter Plant. Define Default Values BACKGROUND This configuration setting enables to define Default values for task list.g. SCENARIO Define default values to the order type YA70 in Plant IND6.
it is suggested to copy from the standard order type.Click Note: . Click . Select PP01 by clicking the grey box in the left.
Click Click Impact of this configuration in Master Data / Transaction When creating the process order.values mentioned in each field can be left as it is.Enter the order type as YP01 Note: . If required it can be changed. . operation number will be assigned automatically if the routing is not found.
. Repetitive Manufacturing:Repetitive Manufacturing is the technique available in PP module to be used for product which are produced with • Least change in setup for manufacturing • Always produced in large quantities • Relatively same items are produced for a longer duration of time without any change in setup Very essential settings to the repetitive manufacturing are • Repetitive manufacturing profile • Product cost collector • Production version • Material master setup The above process are explained in the below steps.9.
9. SCENARIO Create a Repetitive Manufacturing profile. Repetitive Manufacturing profile is the essential setting required for Repetitive manufacturing production method.1 Define Repetitive Manufacturing Profile BACKGROUND This configuration setting enables to define the repetitive manufacturing profile. ü How to carry out back flush ü Which cost is to be captured ü How to reduce the planned order ü Planned order is mandatory or not ü Movement types. Repetitive manufacturing profile defines. INSTRUCTIONS Follow the Menu Path: IMGàProduction à Manufacturing à Control Data à Define Manufacturing Profiles Click Repetitive Repetitive .
AB99 Description of the profile.Update the Following fields Field Rem profile Description of Rem. Auto cost coll. E.g. E. fin.g. Profile Description Key identifying the repetitive manufacturing profile.Backflush .
Select optional radio button to make error correction in dialog mode as optional. Leave this blank Tick this check box to correct error in dialog mode. E. Tick this check box to update the batch where used list.g.Tick this check box to make Backflush and Goods Receipt Tick this check box to create the records of error created during posting Tick this check box to create individual error records. Tick this check box to select the price for backflush material either from standard cost estimate or from preliminary cost estimate from product cost collector. Click Tick this check box to reduce the planned order . Select appropriate radio button to take the price of the material. whether to take from standard cost estimate or from standard cost estimate.
7. Leave it blank Leave SAP settings as it is. E. Leave it blank Enter the number of days in which planned orders are to be reduced.g.g. Tick this check box. Select this radio button to firm the planned orders which are assigned with production line in the planning table already. if it is required to reverse / recreate the planned order when reversing the backflush. Click . E. Leave it blank Tick this check box if it is required to reduce planned order containing any other production version.g.g. E. E. Tick this check to reduce planned order even if it is not assigned with any production version.which contains production version detail. to reduce the planned order in the last seven days.
In this screen no settings are to be done. Click Click Save . Impact of this configuration on the Master Data / Transaction Repetitive manufacturing profile can be used in the material master MRP 4 view for materials which are to be handled in repetitive manufacturing process. .
it is explained along with the configuration of Repetitive Manufacturing Profile so that it will be convenient to the users. Product cost collector is the vital master data for Repetitive Manufacturing process. Product cost collector will define ü Costing variant planned ü Costing variant actual ü Costing sheet With the above input. For each production version there should be a cost collector. similar to the standard cost estimate. Though it is a master data. Product cost collector suggested to be created once the standard cost estimate run for a specific material was completed and updated. Plant and Production version.9.2 Creating product cost collector BACKGROUND This is a master data to be created for every product which are handled in repetitive manufacturing. Product cost collector will be created for the combination of material. separate cost will be calculated to this specific combination of ü Material ü Plant .
ü Production version. SCENARIO Create a Product cost collector. Double click KKF6N . Production version will then be used to for all subsequent cost estimate process. INSTRUCTIONS Follow the Menu Path: LogisticsàProduction à Repetitive Manufacturing à Master Data à Product cost collector à KKF6N Process Product cost collector.
Update the Following fields Field Name Material Plant Field description and value Material code number Enter the plant in which product cost collector needs to be created Click in the left top to create product cost collector Field Name Plant Production version Field description and value Select this radio button to indicate the product cost collector is to the specific production version Enter the plant in which product cost collector needs to be created Enter the production version to which product cost collector needs to be created Click Enter the costing variant planned and actual Click Nothing needs to be maintained here .
E. actual cost incurred will be collected in the product cost collector.Click Enter the costing lot size. . There will be a dialog box asking “Do you want to cerate a preliminary cost estimate for the product cost collector” Click Yes Impact of this configuration in Master Data / Transaction When backflusing for the planned order in repetitive manufacturing.g. 1000 Click Save .
To handle any product in a repetitive manufacturing. With the above three requirement for Repetitive manufacturing. 1. maintained. SCENARIO .3 Required Material Master Settings BACKGROUND Rep. 2. relevant material can be handled in the repetitive manufacturing environment. Repetitive manufacturing Material master must have the following data setup. Production version needs to be Though it is a master data. Mfg.:- This is a master data setup. it is explained along with the configuration of Repetitive Manufacturing Profile so that it will be convenient to the users.9. 3. Repetitive manufacturing check box tick needs to be maintained. Repetitive manufacturing profile needs to be maintained. following are the essential settings required to be done in the material master MRP4 view.
4 digit alpha numeric number may be entered. Enter the valid from Enter the valid to Text Valid from Valid to . Maintain the Repetitive manufacturing profile. Enter the description of the production version.g. Click Field description Version number Field value Enter the production version identity number. INSTRUCTIONS Follow the Menu Path: LogisticsàProduction à Master Data à Material master à Material à Change à MM02 Immediately Double click MM02 Immediately Enter the required material code number Click Select Click Enter Plant.Make material master setting to handle material in repetitive manufacturing. enter your plant value Tick the Repetitive manufacturing check box . E.
g. E. E. E. 1 to consider first alternate BOM Enter the BOM usage. E. Field value Lot size quantity from which this production should be applicable. E. enter 1 Lot size upto which this production version should be applicable. 1 to check the consistency of this production Essential Material master setup completed.g.g.g. Enter 500000 Enter the routing or rate routing group number in the group field. 1 Enter the BOM alternate Number. Impact of this configuration in Master Data / Transaction .g.Click Field description From Lot size To Lot size Detailed planning Group counter Alternative BOM BOM Usage Click version Click Yes Click Click Click Click Save . 50004228 Enter the group counter number.
Backflush to this material can be done with reference to the planned order through transaction code MFBF.Now the material is completely setup to be handled in repetitive manufacturing. .
let’s discuss the Important terminologies. Valuation Variant:Valuation variant will indicate Whether to consider the planned price or moving average price . Before we proceed to the PPCO related configuration settings.10. Machining duration. Labour hours. PP CO Integration:Costing modules are tightly the product and production Production Planning and integrated in costing of accounting. Standard Cost Estimate:Cost of any product contains Material cost – cost derived from BOM (BOM Qty*Rate) Conversion cost – Cost derived from Routing (#Activity * Activity Rate) Over heads – calculated from costing sheet # Setup duration. power consumption are known as Activities. over head charges will be added to it and the final cost of the product will be arrived. Apart from the above two.
Important PP related IMG settings:ü Define valuation of Goods Received ü Define Valuation variant ü Define Costing Variant . i. Assignment of cost component structure will be maintained in costing variant.e. over head calculation Costing Type:Costing type specifies the updation of planned value or actual value in the production order.Whether to consider the planned price of activity for the year Whether Subcontracting price is to be considered from quotation Whether to take the external processing charges from operation Costing sheet. Costing Variant:Costing variant will contain the costing type and valuation variant.
BOM component Quantity x Planned price ( as per the valuation variant it may take planned price to calculate the planned material cost) Actual Cost:Actual cost will be calculated based on the actual component consumption and utility or activity utilization. .g. Target cost will be calculated by the system after the variance calculation is completed.g. Target cost will be compared with the actual cost to calculate the variances. Once the order is crated or released. Cost Calculation process is similar to that explained in standard cost estimate. All right. E. consumed component quantity x Moving Average price Note: . based on the BOM and Routing planned order cost will be calculated.Planned Cost:Planned cost is for information purpose.as per the valuation variant it may consider the moving average price to calculate the actual cost incurred for any order Target Cost:This is similar to the planned cost but it might take the rate detail from moving average price and the component quantity detail as a standard quantity from BOM. E. now we shall look into the configuration related to PPCO integration.
INSTRUCTIONS Follow the Menu Path: LogisticsàProduction à Shopfloor control à Integration à Define Valuation of Goods Received Click .1 Define Valuation of Goods Received BACKGROUND This configuration setting enable to define the valuation of goods received. This is mostly applicable to the material which are defined with moving average price. Valuation at goods receipt controls the price to be considered to the product when it is received through production order or process order after completion manufacturing.10. SCENARIO Define Valuation of Goods Received. We shall display the standard settings as these settings will be done by CO team.
plant Enter Valuation Variant. E.To maintain new entries Click Enter valuation area i. Click Save . 007 – Production order actual. product will be received at the actual cost incurred in the production order irrespective of its standard or moving average price. With the above entry. . while making GR.g.e.
over head calculation SCENARIO Define Valuation variant. i.e.10. We shall display the standard settings as these settings will be done by CO team. Valuation variant will indicate Whether to consider the planned price or moving average price Whether to consider the planned price of activity for the year Whether Subcontracting price is to be considered from quotation Whether to take the external processing charges from operation Costing sheet.2 Define Valuation variant:BACKGROUND This configuration setting enables to define the valuation variant. INSTRUCTIONS Follow the Menu Path: LogisticsàProduction à Shopfloor control à Integration à Define Valuation variant .
Click Let us discuss the standard setting 001 Select 001 valuation variant Click .
Material valuation tab screen define the priority at which the price for material is to be considered Click .
Priority to pick rate for Activity is defined here Click .
Priority to pick the price for subcontracting is defined here Click .
. Note:.When creating the new entry follow the above step and select the priority as per the business requirement.Click Costing sheet may be defined here.
We shall display the standard settings as these settings will be done by CO team. Costing variant will contain the costing type and valuation variant. Costing variant will be referred in all product costing and production order costing.3 Define Costing Variant BACKGROUND This configuration setting enables to define the costing variant. SCENARIO Define costing variant. INSTRUCTIONS Follow the Menu Path: LogisticsàProduction à Shopfloor control à Integration à Define Costing variant Click .10.
Let us discuss the standard PPP1 costing variant Select PPP1 costing variant Click .Standard setting should be sufficient. if required this setting will be defined by the CO module.
Click Click Click .
Note to assign new valuation variant to a Plant Click top. press New entries and follow the above step to assign costing type and valuation variant. Click If new value needs to be created.Valuation variant which we have discussed in the previous topic can be seen here. in the .
Summary: - I am sure. now you are in position to configure the Discrete and Repetitive manufacturing process according to the business blue print to meet the business requirements.11. Friends. .
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