Material master --> BOM --> Resource (CRC1) --> Master Recipe (C201) --> Prod.

version (C223)

Process order (COR1)

Confirmation - COR6N operation wise confirmation, CORKb - Order confirmation

The business process

1,. When you create a process order control recipe will be created if the setting done in CORN.
2.Co60- find PI sheet by giving the order number and enter the details in PI sheet and complete
3. CO54-process message monitor-give the process order number,
it will display the process messages. Choose and click send
the message will be sent to the destination

These are following main T codes used in PP PI

For Process Industry.
Configuration

- Create Order Type for Process Order - T.Code CORN

- Create Order Type Dependent Parameter - T.Code COR4
- Production Scheduling Profile - CORY
- Specify Scheduling Parameter - OPUZ
- Create Control Recipe Destination - O10C
- Create Process Massage Destination - O13C (Optional)
- Create Process Instruction Catagory - O12C (Optional)

Master Data
- Create BOM - CS01
- Create Resource - CRC1
- Create Master Recipe - C201

MRP :- MD61/MD01/MD02/MD03/MD04/MD40/MD41/MD42/MD50.

Production Execution :-
- COR1 - Create Process Order Manual
- COR7 - Convert Plan Order to Process Order
- COR6N/CORZ/CORR - Order Confirmation
- CORS - Cancel Confirmation
- CORT - Display Confirmation
- CO53 - Control Recipe Monitor (Optional)
- CO55/CO60 - Maintain PI Sheet (Optional)
- CO54 - Process Massage Monitor (Optional)
- MB31 - Goods Receipt For Order
- COIK / MB1A / MIGO :- Goods Issue
- KKS1/KKS2 - Calculate Varience
- CO88 - Actual settlement
- COOISPI - Order Information System

Master Data

1. Maintain Material master

2. create a BOM - CS01
3.Create Resource - CRC1
4.Create Master Recipe - C201
5, Create a PV-C223

PRocess folw

1 Create a PIR In MD61 OR requirement will flow from Sale order

 2. run MRP in MD02, or MD01

3. Convert plan order to process order in MD04 or COR7

4. Goods Issue to process order in MB1a or MIGO or in COR6n( if it is auto GI)

5. Confirm operation in COR6N

6. GR for order in MIGO or MB31 or COR6N

7. Calculate over head in KG12/CO43

8. Calculate variance in KKS1 or KKS2

9. Order settlement in ko88 oe co88

Optional

CO53 - Control Recipe Monitor

CO55/CO60 - Maintain PI Sheet
CO54 - Process Massage Monitor

STD REPORT

COOISPI - Process order information system

The below production cycle explains the basic business flow in “Process Industry”. The flow is
generally focusing only on Production and Quality Management

Simple Production Cycle:

Consider all Raw materials are available in plant and production process yet to start, the following
stages are to be followed

1. Create Process Order

Here we are creating a process order based on the capacity of the equipments and resource
availability

2. Release the Process order

Once Process order created, it has to be released for production, means system will check the
scheduling, material availability, capacity planning, etc., and then release process takes place

3. Goods issue from the Stores

Once PO got released, goods issue against the process order will takes place

4. Start processing

Product process against the PO will start

5. Confirmation Process
 After production, the final out put confirmation from the process will be entered

6. Goods Receipt Process

Goods receipt process plays a major role in any business here we have to do 101 movement type
and do the postings. In goods issue process they will issue the goods against PO in 261 movement
type.

7. Quality Approval and Release

Once GR from the production was made, the material will come to Quality control for approval. Here
QC person will check the material and they will do the result recording and usage decision

8. Stock will appear in Unrestricted use for SALE / Further Process

Once usage decision was made the material will automatically moved into unrestricted use. The FG is
ready for sale

By keeping above all points in mind, the following masters and transactions are required to
proceed

S. Master Trans- T-code Description Where has to be used

No action

1 √ MM01 Create Material Used for creating Recipe and further

tracking
2 √ CRC1 Create Resource Machine / set of Machines used for
making the product
3 √ C201 Create Recipe Here we are calling resource and
materials required to make the
finished product
4 √ QS21 Create MIC List of specifications to be checked
for that concerned finished goods
5 √ QP01 Create Quality Plan Creating Quality Plan
6 √ COR1 Create Process Initiating Production Process by
Order creating Process Order
7 √ MIGO with Goods Issue Process Goods issue to Manufacturing unit
261
movement
8 √ CORK Confirmation Production Output confirmation
Process Process
9 √ QA32 Quality Approval QC will approve and release for
and Usage Decision further process

Step by Step Execution Process:

Scenario Explanation:

REQUIREMENTS:

For a leading Process Manufacturing Company ABC, they are selling the product “FG 1”, the raw
materials and resource requirements are listed below

Raw Materials required for making 50kg of Finished Product, FG 1 are

S.No Material Code / Material Description Quantity required Unit of Measurement

 Material Type
1 RM l 1 / ROH Raw Material 1 80 Kg
2 RM 2 /ROH Raw Material 2 20 Kg
3 BP 1 / FERT Byproduct 60 L

Resources required for making 50kg of Finished Product FG1

S.No Resource Code Resource Description Capacity

1 CRC-001 Reactor 2KL
2 CRC-002 Vessel 4KL

List of MASTERS required for addressing the above scenario

1. Create Materials using MM01 transactions in the following way:

In this screen select “select views” button and extend the following fields
We have selected basic information entries field. Fill the information and finally select the General
plant / storage data and give plant as 1100 and storage as 0001 in case of Raw material.

The same procedure has to be repeated for finished goods and Co-Products, in plant storage data we
have to give Plant 1100 and storage 0004.

2. Create Resource master using CRC 1 Transactio

Here we have to mention the Person responsible and standard value type “SAP1 – Normal
Production”.
Here we are planning to give the controlling area and cost center. Finally save the data. The same
procedure has to be repeated for CRC-002

3. Create Recipe using resource and material in T-code C201

In the above screen we have to enter the material we want to produce “FG 1”, and give the plant code
and profile “PI01” then enter.

In the recipe header we have to enter the status as “4” and Usage as “1” , go for Operations screen
Here we have to call the resource and the description details, for example in reactor CRC-001, the
operations like Heating and transfer process will be carried out the same has been explained in this
description field. As per standard value key we have to give the duration for the operation time and
labor time. Both will be taken for scheduling.

In the material tab, we have to enter the version for the BOM and usage details, after that we have to
enter the list of raw materials required for making 50 kg of the FG 1 product. Here co-product is
generating so we have to give the co-product “BP 1” 60 L as “Negative” producing after the process
(NOT as INPUT) and activate as Co-Product by selecting the line item and press items tab and select
co-product tab.

In the header level line item we have the base quantity i.e Finished goods quantity, give 50 and save

Now Recipe is ready.

4. Create MIC using QS21 transaction

Here give the short text, field search and int. char.desc as pH and select the Quantitative check box.
pH have some ranges so, we have to select the limits are upper and lower spec limits.

The same way we have to create temperature also

5. Now create the Quality plan using QP01

Now we are planning to create the quality plans which are to be tested before release from QC

Header data details as above

Then Go to operations and give control key as QM01, select the line item and go to inspection
description tab.

Enter the MIC details here. While entering system will ask the upper spec and lower spec limits. Enter
limits and save

Masters are ready to proceed the Production Cycle

We will start Production Cycle using transactions

1. Create Process Order using COR1

Here give the total quantity as “50” and enter the start date, system will check the scheduling and
capacity planning and finally finish date will come.

Now, once the process is over check the master data, in that we can find the created recipe group for
that material “FG 1”
Now the PO stated us “Created”

Press the Flag button and „Release” the PO for production. After pressing flag button, actually system
will checks material availability, scheduling, capacity planning etc., Once it is over the status of the PO
will be changed to “Released mode”

Save the Process order.

 2. Goods issue against the Process order using MIGO Transaction

Goods issue generally happens from store against the PO with the movement type 261

Once goods issue from the stores is over, the document number will be generated as below
Now go to process order and check the order status “GMPS” will appear, that means Goods
Movement Posted

Now Production process was started and completed. We are going to give confirmation using CORK
transaction

3. Confirmation using CORK Transaction

Once you enter, the yield quantity you have to confirm

Here in MM01, Quality Management views we have to activate the inspection lot origin “04” for
inspection triggering while making Goods receipt using 101 transaction. The following procedure has
to be
adopted.

Select Inspection set up tab and activate 04 inspection type.

This activity has to be done at the time of creation of Master (MM01)

4. Goods Receipt using MIGO with movement type 101

If you check this screen the outputs finished product 1 and co product 1 with the quantities viz., 50
and 60 will be there. We have activated QM view only for FG 1 and not for BP 1 material. So once
GRN was made the material FG 1 will be automatically moved to Quality inspection and BP 1 will be
moved to “unrestricted use”.

At the time of GRN we are creating the batch for FG 1 as “FG00000001”

For BP 1 we are creating Batch as “CO00000001”. The batch can be created at the time of creation of
Process order also.

Here we are mentioning the storage location for the final products “0004”

Once GRN made the document number will be generated for Accounting updates
 5. Quality Approval and Release

Now check the MMBE view, in that the material FG 1 appears in “Quality inspection”

And at the same time BP 1 in which QM was not activated, the stock appears in Unrestricted use
Result recording and Usage decision process for the Material FG 1 batch FG00000001

Go to QA32 and give the inspection lot origin as”04” and press enter

Check the status. The system status should be “RELEASED”

Press “Results” button and do result recording

After entering the actual value the final screen will be like below

Now, go to Usage decision button in the same QA32 Transaction and do accept the batch
Once you save the inspection stock details will come

Enter the stock quantity “50” to unrestricted and check the MMBE view now

Material will be moved to unrestricted use . Now sales process will start.
The above cycle is simple production process generally carried out in “Process industries”

CRC1 - Create Resource

CR24 - Create Resource Network
CR31 - Create Hierarchy
C201 - Create Master Recipe
C251 - Print Master Recipe
C223 - Maintain Production Versions
COIO - Order Info System for PP-PI
COPD - Print Process Order
COPI - Print Process Order ShopFloor Papers
COR1 - Create Process Order
COR5 - Collective Process Order Release
COR6 - Single Process Order Confirmation
COR6N - Single Screen Entry of Confirmations
COR7 - Convert Planned Order to Proc. Order
COR7_PC - Part.Conv.: Plnned Ord. to Proc.Ord.
COR8 - Coll.Conv.: Plnned Ord. to Proc.Ord.
CORK - Process Order Confirmations (Total)
CORM - Mass Processing
CORO - Create Process Order w/o Material
CORR - Collective Entry of Confirmations
CORS - Cancel Process Order Confirmation
CORT - Display Process Order Confirmation
CORZ - Process Order: Time Event Confirmat.
COA6 - Process Order: Archiving
COA7 - Process Order: Retrieval - Archive
COA8 - Process Order: Archive Management
CO56 - Display PI Sheet
CO58 - Maintain PI Sheet
CO59 - Delete PI Sheet
CO60 - Find PI Sheet
COPOC - Process Manufacturing Cockpit
CO53 - Control Recipe Monitor
O10C - Assig. Ctrl Rec. Dest./Proc. Instr.
O12C - Assign Charact. / Proc. Instr. Cat.

MD61 CREATE PLANNED INDEPENDET REQUIREMENT

MD11 CREATE PLAANED ORDER
MD01 MRP RUN COLLECTIVE
MD02 MRP SINGLE ITEM MULTI LEVEL
MD03 SINLE ITEM SINGLE LEVEL
MD04 STOCK-REQUIREMENT LIST(PLANNEC-PROCESS)
MD07 STOCK-REQUIREMENT LIST COLLECTIVE
MD40 MPS RUN(MRP - RUN)
MD41 Single Item Multilevel
MD42 Single Item Singlelevel
MD50 Sales Order Planing - Make to order planing
MD73 DISPLAY TOTAL REQUIREMENT
MD15 CONVERT PLANNED ORDER TO PURCHASE REQ.
MD16 DISPLAY PLANNED ORDER
MD45 PLANNING RESULT
CO24 MISSING PART INFO SYST
CM01 CAPACITY PLANING
CM02 CAPACITY PLANING
CM04 CAPACITY PLANING
MDVP COLLECTIVE AVAILABILITY CHECK(PRODUCT WISE)
MF63 STAGING SITUATION STORAGE LOCATION LEVEL
MD15 CONVERT PLANNED ORDER TO PURCHASE REQUISTION
MD14
MS64 COPY VERSION(CHANGE VERSION FROM INACTIVE TO ACTIVE)
COR7 CONVERT PLANNED ORDER TO PROCESS ORDER
COR8 CONVERT PLANNED ORDER TO PROCESS ORDER
COR1 CREATE PROCESS ORDER (MANUALY)
COR2 CHANGE PROCESS ORDER
COR3 DISPLAY PROCESS ORDER
COOISPI PROCESS ORDER INFORMATION SYSTEM
COHVPI MASS PROCESSING FOR PROCESS ORDER
MC01 LOGISTIC INFORMATION LIBRARY
MC02 INFO-LIBRARY
MC03 INFO-LIBRARY
MR21 PRICE LIST
CM05 CHECK FOR CAPACITY OVERLOD
MD48 CROSS PLANT EVALUATION
COR1 CREATE PROCESS ORDER MANUALLY
O0SC CREATE PROCESS ORDER BY SELECTING PRODUCTION VERSION
COOISPI PROCESS ORDER INFORMATION SYSTEM
COHVPI MASS PROCESSING FOR PROCESS ORDER
COR5 COLLECTIVE ORDER RELEASE
COR7 CONVERT PLANNED ORDER TO PROCESS ORDER
COIK PICIKING LIST
MB26 PICK LIST
MB25 RSERVATION LIST
MB21 CREATE RESERVATION
MB22 CHANGE RESERVATION
MB31 GOODS RECEIPT FOR ORDER
COR6N PHASE CONFIRMATION
CORS DELETE PHASE CONFIRMATION
CORR COLLECTIVE PHASE CONFIRMATION
CO53 CONTROL RECIPE MONITOR
CO55 WORK LIST FOR PI SHEET
CO54 PROCESS MESSAGE MONITER
CO60 FIND PI SHEET
CO64 WORK LIST FOR PI SHEET
CO67 WORK LIST FOR PI SHEET

MINING-
LIME STONE CRUSHING-
RAW MEAL PREPARATION-
CLINKER FORMATION-
FINISH CEMENT GRINDING-
SLAG & CEMENT BLENDING-
PACKING
Mining - where u get the uncrushed limestone
Crushing - where u will make the crushed limestone from uncrushed limestone
Raw Meal Preparation - where additive like iron ore etc are added to
crushed limestone
Clinkerisation - Raw meal is heated in kiln and get the clinker, small
rock or pebble like substances.
Grinding - Clinker along with gypsum is grinded to make cement.
Packing - Cement is either packed in 50 kg bags or in jumbo boxes or
in trucks or ships as per facility in factory.