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SAP Implementation

Project - Talema

USER MANUAL
Production Planning
USER MANUAL
Production Planning User Manual Version 1.0

DOCUMENT CONTROL SHEET

GENERAL INFORMATION

Project name Document name Document location


Talema Production Planning

DOCUMENT INFORMATION
Version Filename Date Autho Reviewed Changes from
r by previous
version
V 1.0 EUT -PP 19-03-
2008

REFERENCE DOCUMENTS

Document Version R Reference

DOCUMENT Submission

Prepared by
Received by

Anand Srinivasan
(Wipro InfoTech Ltd.)

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Production Planning User Manual Version 1.0

USER MANUAL
TABLE OF CONTENTS

___________________________________________________________1
1 MASTER DATA IN PP MODULE...........................................................................................4
2 BILL OF MATERIAL (BOM).................................................................................................14
3 WORK CENTER......................................................................................................................17
4 ROUTING................................................................................................................................24
.............................................................................................................................................27
5 PLANNED INDEPENDENT REQUIREMENTS.................................................................27
6 MRP .........................................................................................................................................31
7 MRP LIST................................................................................................................................35
8 STOCK/ REQUIREMENTS LIST.........................................................................................36
9 PRODUCTION ORDER EXECUTION...............................................................................58
10 PRODUCTION ORDER CHANGE:....................................................................................74
11 CAPACITY PLANNING ...................................................................................................84
12 CAPACITY OVERLOAD: ....................................................................................................90
13 CAPACITY LEVELING- WORK CENTER VIEW( TABULAR):......................................92
14 CAPACITY LEVELING (GRAPHICAL)...........................................................................105
15 CAPACITY LEVELING (ORDERS)..................................................................................109
16 GOODS ISSUE...................................................................................................................117
17 GOODS ISSUE (REVERSAL):..........................................................................................123
18 PRODUCTION ORDER CONFIRMATION:...................................................................125
19 CANCELING PRODUCTION ORDER CONFIRMATION:............................................128
20 GOODS RECEIPT FOR AN ORDER:...............................................................................132
21 STOCK OVERVIEW...........................................................................................................141
22 PRODUCTION ORDER INFORMATION SYSTEM:......................................................143
23 COLLECTIVE CONVERSION OF PLANNED ORDERS:..............................................146
24 REWORK ORDERS:...........................................................................................................148
24 REWORK ORDERS: ..
.148

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SAP R/3 Brief Introduction:

In SAP R3, modular data is classified as Master data and Transaction data.
Master data is defined as the main details of individual modules objects. Typically
in the PP module, main objects are Materials, Bills of Material, Work Centers,
Routings. It contains details about characteristics about those objects like material
type, planning requirements, to produce a certain finished good, what proportion of
semi-finished and raw materials are needed, , work instructions to carry out tasks,.
Whilst Transaction data captures the day-to-day activities and include production
orders, issuing raw materials/ semi-finished materials those orders, receiving
finished goods from the orders. When a transaction is initiated, master data is
transferred into it through logical links.

1 MASTER DATA IN PP MODULE

Material Master

SAP menu Logistics ->Production -> Master Data -> Material


Master ->Material -> Create (General) ->
Immediately
Transaction code MM01

SAP menu Logistics ->Production -> Master Data -> Material


Master ->Material -> Change -> Immediately
Transaction code MM02

SAP menu Logistics ->Production -> Master Data -> Material


Master ->Material -> Display -> Immediately
Transaction code MM03

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Enter Industry sector, choose Mechanical industry from the dropdown; choose
material type from the dropdown. In this case it is semi finished Product. Press
Enter. You will be prompted to choose the required material views. Production
Planning requires the following views viz. Classification; MRP1, MRP2, MRP3, MRP4,
Work Scheduling. Highlight these views and press tick button.

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Enter TSMU or choose TSMU (i.e. Talema mother unit Plant) from the dropdown for
Plant. Choose the Storage Location WPMU from the dropdown. This is where
material is stored. Press Tick.

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You will enter into MRP view no.1 screen.. Choose PD from the dropdown list in the
MRP Type field. PD is the simplest form of MRP type. It is the most flexible MRP
type. PD instructs the system to fine tune the planning... Choose appropriate MRP
controller from the dropdown menu. This is the person who does the planning run.
Choose the Lot Size EX from the dropdown. EX defines that production lot quantity
will vary for every production.

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Press the MRP2 tab. Here, Choose E from the dropdown. This states that this
material is produced in house. Suppose, if a material needs to be procured
externally sometimes, then choose X.

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Press MRP3 tab. Enter Strategy group as 10. This indicates that the strategy
adopted is Strategy No. 10, which is plain vanilla Make to Stock production. Enter
02 in the Availability check field. That is we will use checking group 02 for
availability check.

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Press MRP4 Tab. This view is the most important view of all. It stores essential
details of a material. For materials in Talema with alternate BOMs, for Selection
method field choose 3 from the dropdown menu. This instructs the system how an
Alternate BOM should be selected for a production order. 3 states that Alternate
BOM is selected via a Production version. A Production Version is another PP
master data, which identifies various BOM/ Routing combinations. For Individual/
Coll. Field, for materials which has options of components or assemblies, choose 1
from the dropdown. 1 states that the requirements generated are individually. For
other materials leave this field blank.

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In the same screen, press the Prod Versions button, there will be a pop-up
displaying the list of Production versions of that material. In this case it is S20461.
Click on the Continue button or press Enter.

[ Please note: Creating a Production version is dealt latter in this manual.]

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Press the Work Scheduling tab. Enter the appropriate person in the Production
Scheduler field. For 1008, 008 is the Production Scheduler. In the
Prod.Sched.Profile field, choose 000001 from the dropdown for all the materials.
This profile instructs the system how production is executed in shop floor. Example
as to when the production order should be released, etc.

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2 BILL OF MATERIAL (BOM)

SAP menu Logistics ->Production -> Master Data -> Bills of


Material ->Bill of Material-> Material BOM -> Create
Transaction code CS01

SAP menu Logistics ->Production -> Master Data -> Bills of


Material ->Bill of Material-> Material BOM ->
Change
Transaction code CS02

SAP menu Logistics ->Production -> Master Data -> Bills of


Material ->Bill of Material-> Material BOM ->
Display
Transaction code CS03

BOM is a master data which contains what proportions of input materials are
required to produce a std. quantity of output.

Choose the Material and Plant from the dropdown list.


Choose BOM Usage 1 from the dropdown. ( Usage 1 is Production)

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Enter the Alternate BOM No. Alternate BOMs are alternate combinations of input
materials. 1st Alternate will have 1. 2nd Alternate will have 2 and so on.
Press the Cap button at the top. It symbolizes Header data.

Here, enter, the Base quantity of the Header material as 1. Base quantity is used
as a base for requirements calculation.

Under Alt Text, you can give some text about this alternate say, some keywords for
you to identify later.

Press the Item button at the top.

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Here in the item screen:

Enter the required input materials under the column field Component.
Choose L from the dropdown for all materials.
L means Stock items, where you can stock these materials and
otherwise it is N, which is Non-Stock item.
Enter the required quantities of them under column field Quantity.

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3 WORK CENTER
Work Center is a place, where the conversion of input materials to output takes
place. In ITL, we will using 2 types of work center category viz. (1) Machine 0001;
(2) Labour 0003

SAP menu Logistics ->Production -> Master Data -> Work


Centers ->Work Center -> Create
Transaction code CR01

SAP menu Logistics ->Production->Master Data -> Work


Centers ->Work Center -> Change
Transaction code CR02

SAP menu Logistics->Production->Master Data -> Work


Centers ->Work Center -> Display
Transaction code CR03

Choose the Plant where the work center will be located; Enter the Work Center
name.Choose the appropriate Work center cat. From the dropdown. In this case, it
is 0001.Press the tick button at the top

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For Usage field, choose 009 from the dropdown list. Here, we are instructing the
system to allow all kinds of task list types for this work center.

For Standard value key, choose SAP for Normal Production from the dropdown
menu. Then press tick at the top left of the screen.

For Set up, choose No checking from list


For Machine, choose should be entered from list
For Labour, choose should be entered from list

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Press the Default values tab. Enter Control Key PP01,


For Standard text key, choose the desired one from the dropdown list.
For Printer, choose the desired one from the dropdown list.

For Set up, enter MIN in the Std. Value unit field from list
For Machine, enter MIN in the Std. Value unit field from list
For Labour, enter MIN in the Std. Value unit field from list

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Press Capacities tab.

Enter prime Capacity category as 001. (For assembly Work centers select 002).
Enter SAP006 in Processing formula field. (For assembly Work centers select
SAP0007).

If a secondary capacity exists say, labour enter secondary Capacity category as


002.

Press tick button at the top left.

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You will be presented with the Capacity header screen. Here, you will enter wide
details about the capacity(s).

Enter the name of the capacity as BED LENGTH1100/CENTER HEIGHT. 250; Choose
Capacity planner grp. as 1;.

Choose Factory calendar ID as I8; Active version as 1; Base unit of meas. as HR

Capacity availability times: Enter Start as 08:30:00 till Finish as 00:00:00 the next
day.
Length of Breaks as 03:00:00; Capacity utilization as 100; No. of indiv. cap units as
3;
In Capacity field, enter HR

Indicate for all work centers in the following checkboxes : Relevant to finite
scheduling;
Can be used by several operations; Long-term planning.;

Press the tick button at the top left of the screen.

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Press the Scheduling tab. Here, we indicate that which capacity is used to schedule
this work center. Always use Capacity category 001 to schedule. Processing
formula is SAP002. (For Capacity Category 002 select SAP003.

Work dimension is TIME & Work unit is HR.

Press the tick button at the top left.

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Press the Costing tab.

In the Cost Center choose the appropriate cost center from the dropdown list. By
doing so, we are assigning this work center to the cost center where all the activity
costs will be booked.

For Labour in the Activity Type, choose 1030; in the Activity Unit, enter MIN; in the
Formula field, choose SAP003

Note: Please do not forget to tick the checkbox Ref. checkbox. for all the relevant
activity types. By doing so we are indicating that these parameters are transferred
to Routings where this work center is used. Press tick button and then press the
save button at the top.

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4 ROUTING
Routing is a task list where work instructions regarding how material wise
production conversion takes place in the designated work center are stored.

SAP menu Logistics ->Production -> Master Data ->Routings


->Routings-> Standard Routings->Create
Transaction code CA01

SAP menu Logistics ->Production -> Master Data ->Routings


->Routings-> Standard Routings->Change
Transaction code CA02

SAP menu Logistics ->Production -> Master Data ->Routings


->Routings-> Standard Routings->Display
Transaction code CA03

Enter Material as S20461.


Enter Plant as TSMU, which is our Talema MU
Press the tick button at the top left end.

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Enter the desired task list description by which one can recognize at the time
transactions eg. Production Orders. Here, enter 1008.

Enter Usage always as 1; Status is always 4

In this case, From Lot Size is 1 and To lot size is 99,999,999 and their unit is EA.
Press the tick button. Press the Operations button.

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You will see, Operation step nos. 0010 to 0080. Against each step, choose the
appropriate Work Center, where that operation takes place. In Control key column,
choose PP01 or PP06 for operations, Enter the individual Operation steps in the
Description column viz Winding1:75/1.02 by RW2/15, etc; Enter 1 as Base quantity(
Base quantity is the std. output quantity.); Enter the values for all the costing
activities for each operation viz. Dur M/C HR, Dur Lab HR.

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5 PLANNED INDEPENDENT REQUIREMENTS


So far we have seen the master data. Now we shall see the transaction data.
Planned Independent Requirements (PIRs) are prime input for Production Planning.
Since Make to Stock strategy is adopted at component / assembly across whole of
ITL, PIRs are taken as requirements that are likely to be realized. In other words,
they epitomize the function of their 3 month plan to facilitate raw materials
procurement that has a lead time varying from 20 to 50 days and at the same time
give flexibility to change the production plan at any time, keeping in line with
changing sales situation.

SAP menu Logistics-> Production-> Production Planning->


Demand Management ->Planned Independent
Requirements-> Create
Transaction code MD61

SAP menu Logistics-> Production-> Production Planning->


Demand Management ->Planned Independent
Requirements-> Change
Transaction code MD62

SAP menu Logistics-> Production-> Production Planning->


Demand Management ->Planned Independent
Requirements-> Display
Transaction code MD63

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Enter the desired Req. plan number, say, Anand01, and his Plant as TSMU
Under Planning Horizon, say, enter From as 19.03.2008 and To as 30.05.2008

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Here, enter all the Materials in that Plant TSMU.


Enter the Plant as TSMU for all the Materials.
For each Material, enter the monthly requirements, say for the next 3 months.

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Press the Sched. Lines tab. Here, for materials you need a weekly requirement,
monthly requirement is split by choosing W Week format from the dropdown.

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Press the Table tab again. Now, the weekly split is visible.

6 MRP

MRP Run or Planning Run is an engine which converts the requirements elements

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(Issues) into planned supply elements (Receipts) and Balances the Demand/ Supply
gap. Issues & Receipts are called MRP Elements. Issues include PIRs, Dependent
Requirements, Order Reservations, Sales Orders, Issuing Stock Transfer Orders,
etc. Receipts include Planned (Production) Orders, Purchase Requisitions, Purchase
Orders, Open Production Orders, Receiving Stock Transfer Order, Schedule lines,
etc. Having said that, when we run MRP, Planned orders are generated to offset the
PIRs of Top level materials and Dependent Requirements of lower level products.
These Planned Orders can be converted to actual Production Orders later and are
executed then. Purchase Requisitions are generated for Raw materials, which are
converted to Purchase Orders to fulfill these requirements.

Total Planning: (Plant wise planning)

SAP menu Logistics ->Production -> MRP ->Planning->Total


Planning ->Online
Transaction code MD01

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Total Planning is used planning for all the materials in a plant in 1 transaction.
Enter Plant, as TSMU
Choose Processing Key as NETCH(Net Change in Total Horizon)
Create purchase req. as 2; Schedule lines as 2; Create MRP list as 1
Planning Mode: 3; Scheduling: 2.

Keep pressing the tick at the top left end multiple times and accept all the warning
messages.

Now, press this message box tick to complete the run.

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The above is the result of our planning run. It shows the number of materials
planned.
It also shows the no. of planned orders and purchase requisitions generated, etc.

Single- item multi level planning:

SAP menu Logistics ->Production -> MRP ->Planning->Single item

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multi level

Transaction code MD02

Here, individual material is planned individually.

Enter Material, say, S20461


Enter Plant, TSMU
Processing key, NETCH ( Net Change for total horizon)
Create purchase req. 2
Delivery schedules 2
Create MRP list 1
Planning mode 3
Scheduling 2
Press tick twice

This our MRP results screen.

7 MRP LIST

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MRP list is a static report displaying the detailed results of the planning run
material wise. It displays the time of the MRP Run at the top.

SAP menu Logistics ->Production -> MRP ->Evaluation -> MRP list

Transaction code MD05

This displays the Receipt elements against the Issue elements.

8 STOCK/ REQUIREMENTS LIST

Stock/ Requirements list unlike MRP list is a dynamic report giving you up to date
information about new requirements of that material like PIRs, Issue Stock Transfer
order, Sales orders etc. ( Please note that here Sales orders wont influence

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anything since we are making to stock) and new receipt elements like up to date
Stock level, newly converted Production order, etc)..

SAP menu SAP R/3 Menu Logistics ->Production -> MRP ->Planning-
>Evaluation-> Stock/ Requirements list
Transaction code MD04

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The above is Stock/ Requirements list of a semi-finished level material. Hence, one
finds Dependent requirements and the MRP element which it refers to i.e. all the
4000X level materials.

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Here, we take one of the planned orders which are generated against the
dependent reqts. Say, Planned order no. 0000000006 by double clicking the lens.
You will get this pop-up. Click the pencil image.

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You can change Order quantity to desired value, .

( Note: Alternately, this screen can also be reached by the transaction code MD12
and entering planned order no. 6)

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You can also change the planned order dates and schedule/ reschedule it.
You may want to test the possibility of a new desired date. Enter a new basic finish
date, say 21.02.2008 in place of the old basic finish date. Press Schedule planned
order at the top. The system does Backward Scheduling from that date.

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System has generated new basic dates viz. 02.04.2008 to 02.04.2008. The above
screen displays the routing object of this material to do backward scheduling

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You can also do Capacity Leveling to level the uneven load on the BP, L1( our work
center in our example).

On the menu tree at the top of screen, click Goto and under that click Capacity
Leveling.

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You will get this pop-up input box. Here, click Detailed plnng radio button and Days
radio button.

Enter Period of evaluation as From 19.03.2008 and to 30.04.2008 .

Press the tick in the input box.

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This is Detailed Planning screen. It displays the available capacity for that month
day wise( equipment hrs.) and Total requirements( equipment hrs) every day.

Press the Pegged Requirement button at the top of the screen.

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In pegged requirements, which particular planned order has consumed this


capacity can be traced to.

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As we come down, we find that apparently there is capacity overload as indicated


by overload sign on the left.

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Now we shall look at detail overload view by pressing the Overload button at the
top left corner of the screen.

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Here one can see that the max. load for this WC is 341.5%. Therefore a caution for
us.

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By clicking the + sign on the left side of the capacity, we get elaborate details of
the load. The WC Ruff is shown overloaded for a period of time

Now, press the Overview button at the bottom right of the screen.

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The capacity for all days of the month is displayed, along with overload.

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Now, concurrently, pay a visit at the Stock/ Requirements list of T-Trans1(Torroidal


transformer 18737-P1S01).

Like above we correct and scheduled all the planned which fell on same day

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After correcting and editing the planned orders, we can find in that the capacity is
not exceeding beyond 100%. i.e. capacity is under check!

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We can see that the planned order 0000000048 now has an asterix sign in suffix.
This means that this planned order is firmed. That is this planned order will be
retained and not be replaced by any other planned order when the next MRP is run.

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You can see that this planned order is firmed as the checkbox Plnd order is ticked.

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The Capacity leveling we saw before can also be accessed directly in Stock/
Requirements list( MD04). In the menu tree at the top, click goto and under that,
click Capacity Situation.

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9 PRODUCTION ORDER EXECUTION

We have already created the planned production orders. Now we need to convert
these planned orders into actual production orders and execute. You can create
production orders through one of 3 ways.

(i) Directly from Stock/ Requirements list.


(ii) Entering the planned order no. eg. 0000000048 in the following transaction.

SAP menu Logistics ->Production -> Production Control ->Order-


>Create ->From Planned Order
Transaction code CO40
OR
(iii) Creating a Production order without referring any planned orders.

SAP menu Logistics ->Production -> Production Control ->Order-


>Create ->With material
Transaction code CO01

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Now, let us consider the first 2 methods. From Stock/ Requirements list, by double
clicking the desired planned order, you will get this pop-up. Press ->Prod. ord
button to convert this planned order to production order.

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You will enter into this screen, which is our CO40 transaction.

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You will get the pop up saying that Capacity available at all work centers.

Press the tick in this screen.

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Now press the button Materials at the top of the screen. You will get the message-
All checked materials in order are available. Otherwise you will get the pop-up
Missing parts overview/ Missing parts list. These lists will give the parts which is
deficit quantity.

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You can also view if there is any material shortage. From the menu tree goto ->
Missing parts->Missing parts overview.

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You can view the std BOM quantities required to produce 48 Nos of T-trans1 by
pressing the Component overview button (BOM sign) at the top.

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The above screen shows the std. reqd. quantities of the input materials. You can
also assign respective storage locations of those materials if you want to.

Press the Operations button at the top( next to cap sign).

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This is Operations overview screen, which gives the schedule of this production
order.

Now, double click on one of the operation nos., say, operation no. 0050. to enter
into the operation detail screen.

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This is operation details screen. In this, press the StandardVals tab at the centre.
Here you can see the std. costing activities for that operation. If you have not
entered these std. value at the routing level, you can enter this here at any time
before this order is released.

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Now, press the Cost Order button (calculator sign) at the top.
Press back button twice at the top to come back to main screen.

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Here, press from the menu tree: Goto->Costs-> Itemization

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Here, what you see is the planned costs of this production order.

Now press save button at the top to save the order.

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This production is saved as this number 1000017.

10 PRODUCTION ORDER CHANGE:

SAP menu Logistics ->Production -> Production Control ->Order-

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>Change
Transaction code CO02

Enter the production order no. in the field Order, 1000017.

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Now we need to dispatch the work center to this order. So, we can use this
workcenters for the order.

Highlight all operations; press the menu tree at the top Operations-> Dispatch to
dispatch this order to the work center.

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Now, you can see the column SysStatus, all the operations are having DSPT status.
That is, they are being dispatched.

Now, click the back button at the top to return to the header screen.

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At the top of the screen menu tree, click Goto->Graphic-> Operations.

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This is the operation graphic of the production of this material.

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From the menu tree at the top, press Goto-> Graphic->Gantt chart

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This shows the graphic of operations scheduling using backward scheduling.

[Please note: Now, we will leave this production order 1000017 temporarily
suspended for now. We shall see how Capacity is managed and scheduled to the
exact minute of the day. If this step is to be done, it has to be prior to release of
the production order.]

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11 CAPACITY PLANNING

Capacity Load:

SAP menu Logistics ->Production -> Capacity Planning ->


Evaluation->Work Center View->Load
Transaction code CM01

In this transaction, one can see the weekly capacity load of a work center.

Enter the Work center code, TJ01


Enter Plant, TSMU

Press the Standard overview button at the top.

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The above screen shows, the capacity requirements( equipment hours); available
equipment hours; capacity load( % of total capacity); Remaining available
equipment hours.

You can pick the required week by ticking the checkbox on the left side of that row.
After, selecting, press the Cap. details/ period.

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In this screen, you will see the detailed display of individual load elements and the
source of these load(s) in the column PeggedRqmt. Sources are planned orders &
production orders.

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Now in the same transaction, after entering Work center & Plant, press the button
Variable overview.

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In this screen, you can distinguish the group into Wk. orders (Production orders); Pl.
orders( Planned orders) and sum of the two, etc.

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12 CAPACITY OVERLOAD:

SAP menu Logistics ->Production->Capacity Planning->Evaluation->


Work Center view->Overload
Transaction code CM05

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You can see in this screen that the system displays the weeks in which there is
capacity overload.

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13 CAPACITY LEVELING- WORK CENTER VIEW( TABULAR):

SAP menu Logistics ->Production->Capacity Planning->Leveling->


Work Center view->Planning Table- (Tabular)
Transaction code CM22

Enter the Work Center, TJ01


Enter the Plant, TSMU

Press the filter (funnel) button at the top.

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Choose the Order Cat. as 1 (which means only Production Orders will be displayed)
You can also further filter your criteria with Order, 1000017

You press the execute (clock) button.

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In the top section, tick the checkbox at the left side of the row of the Work center
capacity 001, which is Equipment Hrs.

Now, under the Requirements section beneath, tick the checkboxes at the left side
for all the rows relevant for dispatching. You can see, each operation, operations of
order no. 1000017. We are dispatching the capacities viz. Equipment Hrs.(001).

Press the Dispatch manually button at the top.

[Note: Please recollect whilst creating the work center we had indicated that
although these 2 capacities are used for dispatching, only Equipment Hrs. is used
for Scheduling the work center in the time dimension.]

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You will get this pop-up. In this, tick checkbox at the left side of Equipment Hrs.
row.

Enter the new desired scheduled production dates/ time viz. Start 20.03.2008 at
12:45 hrs. and Finish 20.03.2008 by 24:00 hrs.

Press the Dispatch button at the bottom.

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Now, we check the scheduling results by clicking Extras-> Log-> Planning

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The above is the Planning message box. It says that there are 3 Information
messages; 1 warning messages and no error or termination messages. Former 2
are acceptable but not the latter two.

Click on the right side of Warning messages.

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This screen shows all the 3 messages.

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14 CAPACITY LEVELING (GRAPHICAL)

SAP menu Logistics ->Production->Capacity Planning->Leveling->


Work Center view->Planning Table- (Graphical)
Transaction code CM21

It is ditto same as that of Tabular form.

Enter Work Center- TJ01


Enter Plant- TSMU

Press the filter ( funnel) button.

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Here filter the desired criteria you want.

Choose Order Cat.-1 from the dropdown.


Enter Order- 1000017

Press execute (clock) button at the top.

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The order slabs are in red. Choose each operation and drag it along the desired
date in the X axis time graph by a green color vertical line.

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Now we have scheduled it to new desired dates, operation by operation.

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The above is the planning log message what we get.

15 CAPACITY LEVELING (ORDERS)

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Here, we can level& schedule

SAP menu Logistics->Production->Capacity Planning->Leveling-


>Order view->Planning Table- Order View (Tabular)
Transaction code CM23

Here, enter Order nos. 1000000 to 1000017

Press the filter button at the top, if you want to refine your criteria.

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Enter the filtering data, if any.

Press the execute (clock) button.

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Here, we are selecting the rows of order no. 1000005.

Press the Dispatch Manually button at the top.

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You will get this pop-up. Choose the work center where you want to dispatch and
schedule this order in.

Press the Dispatch Manually button at the bottom left of the pop-up.

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Now we will resume our Order execution 1000017 from where we left.

Remember, we have dispatched & scheduled our order with Start. at 07:00 hrs, on
20.03.2008 & Finish by 11.41 hrs. on 20.03.2008.

Having dispatched this order to new scheduled dates manually, we will release this
production order. Please remember after releasing & saving the order, one cannot
change the order parameters anymore.

Press the Release (Green colour flag) button at the top left.

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Order has been Released

Double click on the Status line.

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You can see that our order now has the Released status.

Click the back (arrow) button to go to main header screen.

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Now, the most important step: Press the save button at the top.

16 GOODS ISSUE

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SAP menu Logistics ->Production->Production Control ->Goods


Movement->Gods Issue
Transaction code MB1A

Here, one can give goods issue to an order.

Enter Movement type as 261 (Always this is the movement type, which has 261)

Enter the Plant as TSMU & Storage location

If you want to print this one, tick the checkbox Print at the bottom left.
Click To Order.

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Enter the Order no. 1000017 Click Adopt Details.

Enter the input materials in the Material column


Required quantities for each material in the Quantity column.
Unit of measure KG in UnE column.
Enter the respective storage location in the column SLoc

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Press the Adopt button.

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Now, press the save button.

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Information Document 4900000140 posted.

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17 GOODS ISSUE (REVERSAL):

Goods Issue Reversal is canceling the Goods Issue given for that order. Goods Issue
can be cancelled for any order any time until the order status becomes CNF, which
is Confirmed.

SAP menu Logistics ->Production->Production Control ->Goods


Movement->Gods Issue
Transaction code MB1A

All details are same except that the Movement type in this case is 262. Enter.

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Enter the Material codes, reversal quantities( mirror image of the issue quantity),
unit of measure, even the same batch no. that was issued before. So, care must be
taken whilst doing this one.

Press tick button at top left of screen. In the next screen, press save button to post.

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18 PRODUCTION ORDER CONFIRMATION:

Production Order Confirmation is a transaction which lets the system know that the
production order execution has been completed. The resulting actual yield
quantity, costing activity actuals like time taken, steam consumed, fuel consumed,
electric power used, etc.

SAP menu Logistics ->Production->Production Control


->Confirmation->Enter-> For Operation->Time Ticket
Transaction code CO11N

Enter, Order no. 8000016

Choose, Confirm. Type Final Confirmation.


Tick the right side checkbox Clear open reservations.

Click the actual data, the system proposes the actual yield quantity of the order &
the actual machine time.

Press the tick button at the top left corner of the screen.

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Similarly confirm the rest of the operations in the production order.

Enter any text you may want to add in the text. For eg. You can give the details
regarding the delay in the order completion as shown above.

Press the tick button at the top left side.


Press the save button.

Alternately we can confirm the at the production order level

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By confirming at the order level, all the operations are confirmed at once

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You can see that the order 8000017 is now having the status CNF, i.e. CONFIRMED

19 CANCELING PRODUCTION ORDER CONFIRMATION:

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SAP menu Logistics ->Production->Production Control


->Confirmation->Cancel
Transaction code CO13

Enter the Order No. 8000017

Press the tick button at the top left corner of the screen.

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You will get this pop-up. Press the Yes button.

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Press the save button at the top.

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20 GOODS RECEIPT FOR AN ORDER:

Goods Receipt is the transaction used for receiving the materials.

SAP menu Logistics ->Production->Production Control ->Goods


Movement->Goods Receipt
Transaction code MB31

Enter Movement Type, 101


Enter Order No. 8000017
Enter Plant TSMU
Tick the checkbox Print, if you want to.

Press the Adopt + Details button at the top.

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[Please note: This step is very important for the order status to get DLV, Delivered.
Otherwise status becomes PDLV, Partially Delivered. For CO users to calculate
variance & settle a production order, status has to be either DLV or TECO]

Press Adopt button at the top left.

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Press the save button at the top to post the document.

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You will get this screen by double clicking at the bottom of the screen, which says
that this Goods Receipt is being posted in the document no. 5000000040.

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Now, we see in the order header screen in the Goods Receipt section. The
checkbox Delivery Completed, is being ticked.

Please note that, suppose in case of production orders having co-products with
indefinite receipt quantities, we may have to do multiple goods receipt
transactions, even if we forget to click del. Comp checkboxes in those transaction,
we can click it here. Till this checkbox is ticked, the order wont have DLV status.

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You can see that our order has the status DLV, Delivered.

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Now, we can see the costs analysis by clicking the menu tree Goto-> Costs->
Analysis

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The above screen gives the analysis of actual costs realized from this order.

Press the Layout (Cube) sign.

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You can select the required columns from being hidden into display by
manipulating the directions.

The desired columns have been added for our display.

21 STOCK OVERVIEW

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In the Stock overview, one can see the display of available stock at any point in
time.

SAP menu Logistics ->Materials Management->Inventory


Management->Environment->Stock-> Stock Overview
Transaction code MMBE

Enter Material 40000004


Enter Plant TSMU

Press the execute button at the top left corner.

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You can see from the above screen that the qty is in unrestricted use

22 PRODUCTION ORDER INFORMATION SYSTEM:

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SAP menu Logistics ->Production -> Production Control


->Information System-Production Order Information
System
Transaction code COOIS

This is prime PP report.

Example, choose Order Headers from the dropdown menu, in List

You can further filter you selection by entering From which Material To which
Material
Or From Production Order No. To Production Order No.

Choose the desired SYSTEM STATUS, eg. If PP person wants to see which all orders
that are CREATED. He shall choose CRTD, Orders created.

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The above is the list of created production orders, which is to be dispatched to


workcenters.

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23 COLLECTIVE CONVERSION OF PLANNED ORDERS:

SAP menu Logistics ->Production -> MRP-> Planned Order->Conv.


To Prod. Ord.- Collective Conversion
Transaction code CO41

This transaction can be used to convert multiple planned orders into production
orders. For example, you can convert all/ some of the planned orders of the any/
some/ all of materials controlled by the MRP Controller. 001 can convert all/ some
of the planned orders of the any/ some/ all of the materials at one go. However,
some care should be taken in choosing the orders to be converted.

Enter Plant, TSMU


Choose MRP Controller from the list , 001
You can filter the selection criteria with Material

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Highlight and select the Planned Order rows.


Press Convert button at the bottom left of screen.

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24 REWORK ORDERS:
Rework order will be differentiated from standard order by order type :PP03

Rework orders can be created manually or automatically using trigger point in an operation

Manually created rework order

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Automatically created rework order will have gear symbol

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Rework order screen

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When going to component overview there is no component assigned in the BOM for
that rework order

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Component have to be assigned manually

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