Production Planning

Agenda

Production Planning - Bill Of Material

Production Planning - Work Centers
Production Planning Routings
Production Planning - Sales and Operation Planning
Production Planning - Demand Management

Agenda (contd)
Production Planning - Materials Requirements Planning
Production Planning - Production Control

Production Planning
Bill Of Material (BOM)

Target Group
Audience: Production planning, design department

Course Objectives
At the conclusion of this course, you will be
able to:
Use the R/3 system to create ,change,display
Bill of Material .
Locate Bill of Material and its related
information in SAP.
Understand the functionality of BOMs.

Contents
Concept of Bill of Material (BOM) in SAP R/3 system
Functions of BOM in production planning and control
Use of BOMs in other areas
Getting Started with BOMs in the R/3 System
BOM Technical Types In R/3

Concept of Bill of materials in SAP

A bill of material is a complete, formally structured list of
the components required to produce the product or
assembly.
The BOM contains the object number of each component,
together with the quantity, unit of measure and item
category of component.
Bills of material (BOMs) contain essential master data for
integrated materials management and production planning
control.

BOM in Production Planning and Control.

Design department work based on BOMs.
Material Requirements Planning (MRP) department
explodes bills of material on a certain date to calculate
order quantities for materials.
Work scheduling department uses bills of material as a
basis for operation planning and production control.

Use of BOMs in other areas.

Sales orders
Reservation and goods issue
Product costing to calculate the costs of materials required
for a specific product

Getting started with BOMs in R/3

Variant BOMs:

A variant BOM groups together BOMs of several similar products that

describe different objects (for example, products) with a lot of common
parts.

Multiple BOMs:

A multiple BOM groups together several BOMs that describe one object
(for example, a product) with different combinations of materials for
different processing methods. One product can be manufactured from
alternative combinations of materials depending on the quantity to be
produced (lot size). Usually the only difference is in the quantity of
individual components.

BOM Usage
It allows you to maintain individual BOMs for any area
(design, production) of your company.
These BOMs are maintained independently of each other.
In this way, each area is only dealing with the specific data
it requires.

Item Categories and Item Data

For each components/items of any BOM an item category
should be assigned.
The item category defines the features and functions of an
item.
The item category determines which specific item data is
processed and controls further activities in the system.
Sub items can be maintained.

Item Categories and Item Data (contd)

The standard R/3 System contains the following item
categories:
Item Categories for Material Items

Stock Items

Non Stock Items

Variable Size Items

General Item Data (contd)

Recursiveness Check

A BOM is recursive if the product contains a component with the same

object number as the superior assembly.

Alternative Items in an Alternative Item Group

Group items in a BOM in which any of the materials in the entire item
group could be included in the assembly. These items are known as
alternative items in the BOM and group is called as Alternative Item
Group

BOM Reporting Functions

The R/3 System supports the following reporting functions:

Mass change: You can use the mass change function to change items in
several BOMs at once.

BOM Explosion: The system determines all the components which are
contained in an assembly.

BOM level by level

Multi-level BOM

Where-Used List :To determine which BOMs an object is used in.

BOM Comparison: Two BOMs can be compared for single or multilevel .

Displaying Change Documents

Production Planning
Work Centers

Target Group
Audience: Production planning department.

Course Objectives
At the conclusion of this course, you will be
able to:
Use the R/3 system to create work center.
Locate work center and its related information in
SAP.
To understand role of work center in production
planning.
To create, change, display work center in SAP.

Contents
Work centers
Concept of work centers in SAP R/3
Work center data in R/3

Basic data

Default values

Capacity Data: Concepts

Standard available capacity

Interval of available capacity
Units of Measurement for Available Capacity

Work centers
A work center is a place where production operations are
performed.

Machines, machine groups

Employees, groups of employees

Together with bills of material and routings, work centers belong to the
most important master data in the R/3 production planning and control
system.

Work centers are used in task list operations (routings) and integrated
with Human resource management system .

Concept of work centers in SAP R/3.

A work center is created for a plant and is identified by a
key.
To each work center a work center category is assigned,
that determines which data can be maintained in the work
center.

Work center data in R/3

The data is grouped together in screens and screen
groups. Examples of such screen or screen groups are:

Basic Data

Assignments (to cost centers, Human Resource Management System

(HR))

Capacities

Scheduling

Default values

Hierarchy

Basic data
In the Basic data screen the following data is maintained.

Short and long texts for description of work center.

Various administrative data, such as the person responsible and the

location of the work center

Usage type: This specifies which type of task lists the work center can be
used in.

Basic data (contd)

Standard value key:Standard values are planned values for the execution
of an operation and are maintained in the operation.

E.g.:set-up and processing

The execution time, costs and capacities are calculated in operations using
formulae from the work centers and standard values from the operations.

Performance Efficiency Rate Key :The performance efficiency rate key is

the ratio between an individual's actual output and the planned average
output .This refer to standard values

Default values
You can enter default values for operation and suboperations in work centers.
The default values are then copied when you assign the
work center to the operation or sub-operation.
By entering default values you reduce the effort necessary
in editing operations.
Some of default values entered are

A control key determine how an operation or a sub-operation is to be

processed in a task list.

Standard text.

Units of measure of standard values.

Capacity Data
Capacity is the ability to perform a specific task.
Capacities in work centers are distinguished by capacity
categories. Capacity categories are for example:

Machine capacity

Personnel OR labor capacity

Each capacity category can be used once in each work center.

For every capacity category you can maintain several

available capacities .

Scheduling Data
Scheduling basis

The scheduling basis is a capacity whose operating time is to be used for

scheduling orders.

Formulas

Formulas are used to calculate the execution times of operations in

production orders using standard values

Interoperation times:

The interoperation time is the time between leaving one work center and
beginning the operation at the next work center. It consists of the move
time and the queue time before processing starts.

Cost center data

Work center is assigned to activity types.
Activity types are used to describe the various forms of
activity that are performed at a cost center.
The activity types are used to calculate the costs for these
activities.

Production Planning
Routings

Target Group
Audience:Production planning department.

Course Objectives
At the conclusion of this course, you will be
able to:
Use the R/3 system to create Routing.
Locate Routing and its related information in
SAP.
Understand the role of routings in Production
planning

Contents
Routing in SAP R/3 system.
Structure of routing.
Identification of routings.
Header data
Sequences
Standard sequence
Parallel sequence
Alternative sequence

Routing in SAP R/3 System

A routing is a description of

Which operations (process steps) have to be carried out

The order in which they are carried out,

Information about the operations .

Details about the work centers at which they are carried out

About the required production resources and tools (includes jigs and
fixtures).

Standard values for the execution of individual operations to produce the

material (product).

A routing is used as a source for creating a production

order.

Structure of Routing
A routing is composed of a header and one or more
sequences.
The header contains data that are valid for the whole
routing.
A sequence is a series of operations.
Operations describe individual process steps, which are
carried out during production.

Identification of Routings
Every routing is identified by material number and plant .
In SAP routings can also be identified by its group and its
group counter .
A group combines task lists (routings) that

Describe similar production processes

Are used to produce similar materials

Header data
This is the data that is valid for the whole routing.

The status and usage of the routing.

The planner group responsible for maintaining the routing

The QM data you decide:

Whether the inspection is carried out using inspection point or not.

Whether the inspection scope is to be adjusted dynamically and if so, at

which level.

Enter a long text with explanations and notes for the

header.
Routings can be classified .

Sequences
A linear List of operations (production steps), which are
carried out after another, according to their operation
numbers.
A sequence contains a number of consecutive operations.
A sequence is subordinate to the routing header.
In the simplest case a routing only has one sequence, the
standard sequence.
Every other sequence is either an alternative or a parallel
sequence, depending on whether its operations are
performed as an alternative to the standard sequence or in
parallel (at the same time) with the standard sequence.

Sequences (cont..)
Enter a lot size, if you want the system to automatically
select an alternative sequence based on the lot size.
If in production process ,several operations are to be
processed simultaneously, create one or more parallel
sequences.
Specify where floats exist due to operations with differing
duration being executed at the same time.

Standard Sequence
The system automatically creates the standard sequence,
when a routing is created.
The standard sequence serves as a reference sequence for
parallel and alternative sequences.

Parallel Sequence
A linear sequence of operations that is parallel to a
sequence of operations in the standard sequence.
A parallel sequence enables to process several operations
at the same time.
A parallel sequence is carried out at the same time as the
corresponding section in the standard sequence.
It is a special form of overlapping operations.

Alternative Sequence
A linear sequence of operations that is an alternative to a
sequence of operations in the standard sequence.
You use an alternative sequence for example, if

The production flow is different for certain lot-size ranges

e.g. Use of NC machines or conventional lathe may depend on the lot size.

The production flow changes under certain business conditions.

For instance, if you have a capacity problem, you have some production steps
performed externally by a vendor

Component Allocation
Material components in a BOM that are not allocated to an
operation in the routing are automatically allocated to the
first operation when a production order is created.
If a phantom assembly is allocated to an operation in a
routing, the system automatically allocates all of the
material components in the phantom assembly to the same
operation as the phantom assembly when a production
order is created.

Production Resources/Tools
Production Resource/Tool(PRT) is a moveable operating
resource used in production or plant maintenance.
Production resources/tools can be assigned to operation,
activities or phases in task lists (including standard
networks and recipes), production orders and maintenance
orders as well as networks.
Production resources/tools that are used for testing during
production, can be assigned to the corresponding
inspection characteristic in the inspection plan.

Scheduling in Routings
Scheduling can be used to calculate the in-house
production time of a material and compare it to the lot sizeindependent in-house production time from the material
master record. The lot size-independent in-house
production time from the material master record can then
be automatically or manually adjusted.

Production Planning
Sales and Operations Planning

Target Group
Audience: Planning departments

Course Objectives
At the conclusion of this course, you will be
able to:
Use the R/3 system to create sales and
operation plans .
Understand role of sales and operation planning
functionality.

Contents
Concept of SOP
Product Group
The Forecast in SOP
Rough-Cut Planning Profiles
Version Management: Concepts
Aggregation and Disaggregation
Methods for Creation of Production Plans
Working on SOP
Transfer to Demand Management

Concepts of SOP
Sales & Operations Planning (SOP) is a flexible forecasting
and planning tool
Sales, production targets can be set on the basis of
historical, existing, and estimated future data.
Rough-cut planning can be carried out to determine the
amounts of the capacities and other resources required to
meet these targets.
SOP is used to perform companys sales and production
operations.

Concepts of SOP (Contd)

SOP constitutes the planning functionality in SAP
SOP plans are passed on to Demand Management in the
form of independent requirements
This data is fed to Material Requirements Planning (MRP)

Product Group
Product group data is planned in standard SOP.
A product group combination of other product groups and
materials according to whatever criteria best meet the
needs of an enterprise.
Product groups are classified according to whether they are
multi-level or single-level.
A product group is multi-level if it contains other product
groups. However, the lowest level in a product group
hierarchy always consists of materials.
A product group is single-level if its members are materials
only.

Forecast in SOP
To estimate the future progression of values in a time
series on the basis of past history using With the forecast,.
either online or in the background

Rough-Cut Planning Profiles

In a rough-cut planning profile, the requirements of one or
more of the following resources are planned:

Work center capacities

Materials (typically, raw materials)

Production resources/tools

Costs

These are the resources required to meet a sales target,

production target, purchasing target, that has been set for
a material, product group.

Version Management: Concepts

Sales & Operations Planning (SOP) allows you to plan the
same information structure as often as you like
Each planning version is stored under a version number
with a description.
Different planning scenarios can be constructed for one
information structure.
A version number is numerical and consists of three digits.

Active versus Inactive Versions

Only one planning version of an information structure is
"active". This is version A00.
All the other planning versions are "inactive".
A version is automatically active if it is the only planning
version that exists for an information structure.
If several versions exist, the active version is the first one
created .

Production Planning
Demand Management

Target Group
Audience: Production Planning department .

Course Objectives
At the conclusion of this course, you will be
able to:
Use the R/3 system to create demand program.
Understand strategies for production.
Understand the role of demand management.

Contents
Demand Management
Strategies for Make-to-Order Production
Strategies for Make-to-Stock Production
Consumption Strategies
Consumption period

Demand Management
The function of Demand Management is to determine requirement
quantities and delivery dates for finished products and important
assemblies.

The result of Demand Management is the demand program. The demand program is
created in the form of planned independent requirements.

Demand Management uses planned independent requirements and

customer requirements. Customer requirements are created in sales
order management.
To create the demand program, planning strategy must be defined
for a product.
Planning strategies represent the methods of production for
planning and manufacturing or procuring a product.

Strategies for Make-to-Order Production

This strategy applies to production of a material for a specific
individual sales order.
Finished products are not produced until a sales order is
received.
Make-to-order is also used in the following environments:

Production using variant configuration

Assemble-to-order

This is due to the close relationship between the sales order and
production that exists in a make-to-order environment and that
is required in assemble-to-order and variant configuration.

Strategies for Make-to-Stock Production

Production of goods without having sales orders , i.e stock
is produced independently of orders
Goods are provided to customers immediately with goods
from that stock.
Make-to-stock strategies can support a very close
customer-vendor relationship, because goods are
provided to customers from stock as quickly as possible.
For a finished product planning with final assembly is most
commonly used under this strategy.

Consumption Strategies
The consumption mode determines how customer
requirements consumes planned independent
requirements
In backward consumption, the system looks for the
planned independent requirement quantity that lies directly
before the sales order.
In forward consumption, the system looks for the planned
independent requirement quantity that lies directly after the
sales order.
Maintained in MRP Screen of material master.

Consumption period
The consumption period is maintained in the material
master record (MRP screen)
The consumption period (either forward or backward) is
specified in workdays and is valid from the current date.
Sales orders, material reservations, dependent
requirements then consume the planned independent
requirement quantities that lie within the consumption
period and after (for forward consumption) or before (for
backward consumption) the requirements date.

Production Planning
Material Requirements Planning (MRP)

Target Group
Audience: Production planning department.

Course Objectives
At the conclusion of this course, you will be
able to:
Run MRP for individual materials as well as for
the plant .
Evaluate MRP results

Contents
Material Requirements Planning in R/3
Master data for MRP
Concepts of MRP
Role of MRP controller
Planning Configurable Product
Control Parameters for the Planning Run
Evaluating the Planning Result

Material Requirements Planning in R/3

Functions of material requirements planning is

To guarantee material availability.

It is used to procure or produce the requirement quantities on time both for

internal purposes and for sales and distribution.

Monitoring of stocks, creation of order proposals for purchasing and

production.

Determines any shortages and create the appropriate procurement

elements.

Create messages that inform the MRP controller of critical parts and
exceptional situations so that the MRP controller can quickly reprocess the
results of the automatic planning run in the specific area with problems.

Master Data for MRP

Material Master

BOMs

Work Centers

Routings

Demand Management

Sales and Distribution, if necessary

Concepts of MRP
Single-Item or Total Planning. For an individual material,
plannig is referred to as single-item planning. For a certain
plant, where all materials to be planned are included in the
corresponding plant, it is referred to as total planning.
Scope of the Planning Run

Regenerative Planning: All materials are planned for a plant. Usually, the
regenerative planning run is only carried out in the implementation
stages.

Net Change Planning: Only materials which are included in the planning
run are those which have undergone a change relevant to MRP since the
last planning run

Concepts of MRP (contd)

Net Change Planning in the Planning Horizon: only those materials are
planned which have undergone a change relevant to MRP within the
planning horizon.

Assembly processing: The system automatically creates

either a planned order (run schedule quantity) or a
production order when you create a sales order for a
material with assembly orders.
Lot-Sizing Procedures

Static lot-sizing procedures:Using quantity specifications entered in the

material master record.

Lot for lot order quantity

Fixed lot size
Replenish up to maximum stock level

Concepts of MRP (contd)

Manual Reorder Point Planning

Specify both the reorder level and the safety stock level manually in the
material master record.

Automatic Reorder Point Planning

Both the reorder level and the safety stock level are determined by the
integrated forecasting program , using past past consumption data
(historical data) to forecast future requirements.

Concepts of MRP (contd)

Forecast-Based Planning: Calculation of future
requirements using historical data, carried out at regular
intervals.
Planning Calendars: To specify flexible period lengths for
period lot-sizing procedure for MPS and MRP. The system
groups the order proposals created in the period defined in
the planning calendar into one lot.

Concepts of MRP (contd)

Phantom Assemblies

Represents a logical grouping of materials from the construction point of

view and are not from the production point of view, the dependent
requirements of the higher-level assembly are directly passed on to the
components of the phantom assembly and planned orders or purchase
requisitions are created for these components.

Availability Check

The function of the material availability check is to make sure that

requirements are covered by existing stock or by planned inward
movements.

Backorder Processing:

The option of processing missing parts from list of receipts and issues for
a particular material that are relevant for the availability check.

Concepts of MRP: Reorder Point Planning

Role of MRP controller

The MRP component assists the MRP controller in his area
of responsibility and relieves the controller of routine
material monitoring.
The MRP controller is responsible for all activities;for
specifying the type, quantity and time of the requirements
He must also calculate when and for what quantity an order
proposal has to be created to cover these requirements.
He is provided with the information on stocks, stock
reservation and stock on order to calculate quantities and
he needs all the information on lead times and procurement
times to calculate dates.

Role of MRP controller (contd)

The MRP controller determines a suitable MRP and lotsizing procedure for material to determine procurement
proposals.
The planning run in MRP determines any shortages and
creates the appropriate procurement elements.
The system creates messages that inform the MRP
controller of critical parts and exceptional situations so that
the MRP controller can quickly reprocess the results of the
planning run in the specific area with problems.

Scheduling
During scheduling, production and procurement dates are
determined for materials that are produced in-house and for
materials that are procured externally.
Scheduling: In-House Production

Scheduling for in-house production is carried out in two phases:

Calculating the basic dates for planned orders

Basic dates are determined for the planned orders created by MRP, that is, the
order finish date and the order start date.

The order finish date determines the latest possible date by which production
has to be finished and the order start date determines the earliest possible
start of production. Basic dates are calculated automatically during every
planning run.

Scheduling (contd)

Calculating production dates (lead time scheduling)

Lead time scheduling determines the production dates, that is, the target start
date and the target finish date. Additionally, capacity load records are created.

The basic dates determine the outermost time limits for production. MRP
determines the order start date, order finish date and planned opening date of
the planned order.

The following times are taken into account when

calculating the basic dates:

Goods receipt processing time in workdays

In-house production time in workdays

Scheduling (contd)
Scheduling for External Procurement
Only the basic dates for procurement elements are
determined for external procurement.
The following times are taken into account for scheduling
materials that are procured externally:

Processing time required by the purchasing department (workdays)

Planned delivery time of the material (calendar days)

Goods receipt processing time (workdays)

For the purchase requisition, the following dates are determined:

Delivery date (which corresponds to the finish date)

Release date (which corresponds to the start date)

Control Parameters for the Planning Run (contd)

Net change planning in the planning horizon is another
version of net change planning which shortens the MRP
planning run even further.

With this version, MRP is only carried out within a defined planning horizon.

Changes outside the planning horizon are not taken into account.

This means that only those materials are planned which have undergone a
change relevant to MRP within the planning horizon. To plan the changes
outside the planning horizon, you must carry out a net change planning run
in larger time intervals.

You specify the planning run type to be used in the initial

screen of planning, in the Processing key field.

Control Parameters for the Planning Run (contd)

The creation indicator is used to define whether planned
orders, purchase requisitions, delivery schedules and MRP
list are created during the planning run.
Using the creation indicator, which only refers to materials
that are procured externally, you can control which of the
following is to be created:

Planned orders only

Purchase requisitions only

Purchase requisitions within the opening period and planned orders

outside the opening period

Control Parameters for the Planning Run (contd)

Creation Indicator for Purchase Requisitions
Planning Mode in the Initial Screen
For single-item planning as well as total planning, you can
also use the planning mode to control whether:

Existing planning data is to be reactivated (planning mode 1)

Whether the BOM is to be re-exploded (planning mode 2)

Whether new receipt elements are to be created for all issue elements
(planning mode 3)

Control Parameters for the Planning Run (contd)

Scheduling Indicator

Indicator to define whether lead time scheduling is to be carried out for

the calculation of the basic dates (planned dates) for materials produced
in-house.

Lead time scheduling calculates the precise start and finish dates for
production. The system only creates capacity requirements if lead time
scheduling has been carried out.

Displaying the Planning Result

If this indicator is selected , the system displays a screen
with the planning results where you can change existing
order proposals or create new ones

Evaluating the Planning Result

The fast access to exceptional situations and all relevant
information reduces the workload of the MRP controller and
provides an environment where he can quickly react to
problem situations.
The following options are available for reprocessing the
planning result:
Planning result of single-item planning

In single-item planning, the result can be checked before it is saved. You can
change, reschedule, or even create new order proposals before the system
saves the result in the database. This function is valid for single-level and
multi-level planning. In multi-level planning, you can check every component
in the BOM or you can select certain components for reprocessing.

Evaluating the Planning Result (conts)

Stock / requirements overview per material

The contents of the stock/requirements overview corresponds to the contents

of the MRP list.

However, current changes to the stock/requirements situation (goods receipt,

opening of a purchase order, and so on) since the last planning run are reread each time you access the list which means that they are immediately
visible.

Thus, the MRP controller has a means of accessing an overview of the current
material availability situation at all times.

Production Planning
Production Control

Target Group
Audience: Production planning department.

Course Objectives
At the conclusion of this course, you will be
able to:
Use the R/3 system to create Production orders
Enter confirmations for time tickets.
Get information on shop floor.

Contents
Production orders
Methods of creating production orders
Production order Data.
Scheduling
Checking the Availability of Material
Release of production order
Confirmations
Order Settlement
Production Order Information System

Production Orders
Production orders are used to control production within a
company.
A production order defines

Which material is to be processed or produced

At which location I.e work center.

At what time( when to produce ? )

How much work(quantity) is required.

Which resources are to be used and

How the order costs are to be settled.

Methods of Creating Production Orders

An order can be generated in the following ways:

By converting a planned order to a production order

Without any previous requirement, that is by creating it manually

Release of Production Order

When a production order is created the following actions
are carried out:

A routing is selected, its operations and sequences are Transferred to the

order.

The bill of materials is exploded and the items in the bill of material are
transferred to the order.

Reservations are generated for bill of material items held in Stock.

The planned costs for the order are generated.

The capacity requirements are generated for the work centers.

Purchase requisitions are generated for non-stock items and externallyprocessed operations.

Production Order Header Data

This data appears in a tab form with the following tab
pages:

Header: Quantities, dates and scheduling data.

Allocation: Created/changed by, responsibility, plants, other assignments

Goods receipt: Tolerances, receipt and delivery

Master data: Reference order, costing data, production scheduling profile

Dates/quantities: Details of quantities, dates

Basic data: Routing, bills of materials

Production Order Operation Data

This data is maintained in operation overview screen.
The following information is listed for every operation on
this screen:

The operation number (this number specifies the sequence in which

operations are processed).

The suboperation number of existing suboperations

The work center where the operation is to be executed

The control key that determines how the operation is to be used (for
example, whether it must be confirmed, whether it can be scheduled,
whether it can be printed, and so on)

Production Order Operation Data (contd)

The current status of the operation (for example, whether it has already
been created or released)

The start and finish date of the operation

A short description of the operation

There are also the columns Comp, PRT :

If the column COMP has an indicator that means that components are
allocated to the operation.

If the column PRT has an indicator that means that production

resources/tools are allocated to the operation.

Production Order Component Data

If a bill of material exists for the material to be produced,
the BOM items contained in the bill of material are
automatically taken over into the production order as
components.
The following information is also taken over for each BOM
item:

Item category: The item category determines how the component is dealt
with in the order:

Costing relevancy: This indicator specifies that the

component is fully relevant to costing.

Production Order Component Data (contd)

Bulk material indicator: This indicator is either picked from
routing, or material master, or work center.
The following key is taken over from the material master
record of the component:

Indicator: "Phantom assembly": If a component is marked in its material

master record as a phantom assembly (special procurement key on the
1st MRP screen), this indicator is taken over into the order for the
component.

In the production order components must always be allocated to an

operation. All components that were not already assigned to a specific
operation in the routing are allocated by the system to the first operation
when the order is created. However, you have the option of adding
components from one operation to another

Other Data in Production Order

Production resources/tools

Production resources/tools (PRTs) are, in contrast to machines and fixed

assets, moveable resources that are not tied to a particular location and
can be used several times. In the production order production
resources/tools must always be allocated to a specific operation.
However, the allocation can already take place in the routing.

Scheduling
Scheduling Types
You can schedule a production order using the following
scheduling types:

Forward scheduling: If you use this scheduling type, the system

schedules forward starting from the order start date.

Backward scheduling: If you use this scheduling type, the system

schedules backwards starting from the order finish date.

Scheduling to current date: If you use this scheduling type, the system
takes the current date as the order start date and schedules forward.

Checking the Availability of Material

Before you start with production, checking is to be done
whether all the material components allocated to the
production order are available on the calculated
requirements dates.
In a production order, the system can only check a material
component, if it is

Kept in stock or not

Checking the Availability of Material (contd)

If, during an availability check, the system determines that
a component is not available on a date on which it is
required, the production order is automatically given the
status "Missing part" (MSPT).
This status remains active in the order header until a
subsequent availability check (overall check) determines
that all components have become available (for example,
due to a goods receipt).
It is possible to display missing parts in the SAP System.
You can display data

Release of Production Order

The following restrictions apply to a production order with
the status "created and which is not released.

Completion confirmations cannot yet be carried out for the order.

Shop papers cannot be printed.

Stock movements cannot be carried out for the order.

The release of the order cancels these restrictions.

Printing orders is possible once the order is released.
Scheduling

Confirmations
A confirmation documents the state processing of orders,
operations, sub-operations and individual capacities. It is
an instrument for controlling orders.
With confirmation you specify

The quantity in an operation that was produced as yield, scrap and the
quantity to be reworked

Dates

How much work was actually done

Which work center was used for the operation

Reason for variance

Long text

Confirmation (contd)
Usually confirmations are made for

An order

An operation

Rework
It is sometimes necessary during or at end of a production
process to execute additional operations in order to
improve components or products with insufficient quality.
These additional processing steps are referred to as
rework.

A production order is created for 20 shafts. After a turning operation you

carry out an inspection operation to check the tolerances. 5 shafts are
found to be outside the tolerances. By reworking you can enter these 5
pieces as yield.

You therefore insert a rework operation where the 5 pieces are turned a
second time

Order Settlement
When a production order is settled, the actual costs
incurred for the order are settled to one or more receiver
cost-objects (for example, to the account for the material
produced or to a sales order). Offsetting entries are
generated automatically to credit the production order:

If the costs for the production order are settled to a material account, the
order is credited each time material is delivered to stock. The material
stock account is debited accordingly.

Production Order Information System

The production order information system is a tool which
offers Shop Floor Control the following functionality:

Reporting

Mass processing

All orders that exist in the system can be included in the

evaluations (including those with deletion flags / indicators.
Archived orders are, however, not taken into account.
The Production Order Information System offers various
list types in reporting.
Their layout can be adapted to suit your requirements.

Production Order Information System (contd)

You can select production orders according to the
following criteria:

Plant

Order type

Material

MRP controller

Production scheduler

Work center

Component

Sales order

Production Order Information System (contd)

Selection profiles

You can enter a selection profile, which selects orders by their statuses
(system status or user status at header level)

Deletion flags

You can specify whether orders in which a deletion flag is active should
be taken into account during selection.

Production Order Information System (contd)

The object overview displays the objects selected from the
production orders in hierarchical form.
This makes it easy to see the relationship between the
individual objects (for example component allocated to an
operation or confirmation allocated to an order header).

Production Order Information System (contd)

Every object selected from the database can be

Displayed in the object overview, or

Displayed in the detail list

Each detail lists contains detailed information on the

object.

You want to display all PRTs that were used during a particular period..