Material Master, BOMs, and Task Lists
Unit Overview
This unit explains material master, bill of materials, and task lists. It also explains how to create a material master record, maintain a super BOM, and maintain task lists.
Unit Objectives
After completing this unit, you will be able to:
• Create a material master record, including control parameters for sales and Material Requirements Planning (MRP)
• Maintain a super BOM without dependencies with class items and configurable assemblies
• Maintain task lists and routings without dependencies with additional sequences, suboperations, and Production Resources/Tools (PRTs)
Unit Contents
Lesson: Creating a Material Master Record... 58 Exercise 4: Material Master Maintenance ... 63 Lesson: Maintaining a Super BOM ... 71 Exercise 5: BOM Maintenance (Without Dependencies) ... 75 Lesson: Maintaining Task Lists ... 85 Exercise 6: Routing Maintenance (Without Dependencies) ... 89
Lesson: Creating a Material Master Record
Lesson Overview
This lesson explains how to create a material master record, including control parameters for sales and Material Requirements Planning (MRP).
Lesson Objectives
After completing this lesson, you will be able to:
• Create a material master record, including control parameters for sales and Material Requirements Planning (MRP)
Business Example
ABC Motors is an automobile manufacturing company. It manufactures various models of cars. The company is implementing variant
configuration solution to maintain end-product variants. To implement this process, you, as the Product Manager of the company, need to create the material master record.
The material master record collects information and control quantities for the configurable product.
The bill of material and routing or task list carry the object dependencies.
Figure 29: Variant Configuration Knowledge Base for Materials (2)
Configurable Material
• Material number under which all variants of a product are stored in SAP R/3 Enterprise
• Point of reference for all related objects, such as bill of material, routing, and so on
• Sets important control parameters, in particular for MRP, pricing, and sales
The configurable material (standard product, in earlier releases) is the material number under which all variants of a product are stored in SAP R/3 Enterprise.
The material master record is the reference point for further objects that are relevant to the variant product. Bills of material, routings, and so on are all created for this material.
The material master record contains important control parameters, which especially affect Material Requirements Planning (MRP) and sales.
Views for Material Master Maintenance
Figure 30: Views for Material Master Maintenance
Material master records are also referred to as materials and part masters. Each department has its own view on a material master record. For BOM maintenance, it does not matter which views exist, provided that at least one view exists at the plant level.
In Customizing for bills of material, you can define which material types can be used to create BOMs and which material types are not allowed in BOMs.
The material status must allow BOM maintenance.
The user-specific material master allows you to tailor the data displayed to meet your specific requirements.
You can define default settings for the views, the industry sector, and the organizational levels.
Settings for Configurable Materials
Figure 31: Settings for Configurable Materials
In the standard system, material type KMAT is defined for configurable materials. You can define a material as configurable even if the material has a non-configurable material type, by setting the indicator on the basic data screen of the material master.
You must define the following configuration-specific settings in the material master of a configurable material.
In the sales data, you enter the item category group. The item category group controls the assignment of item categories in sales orders. The item category of an item influences the transfer of requirements and pricing for the item.
In the MRP data, you enter an MRP group or a strategy group. The strategy group determines the planning strategy for the configurable material, for example, make-to-order production. The MRP type determines whether and how the material is planned, for example, using planned orders. The lot size determines the lot-size procedure that the system uses to calculate the quantity of the material to be produced. A configurable material needs exact lot sizes.
The Individual/Collective indicator controls whether separate segments for requirements for the configurable material are created in the MRP requirements explosion.
To enable availability checks for the material and its components, enter a checking rule. The default checking rule for a configurable material is 02.
To enable Order Change Management (OCM), define the profile in the work scheduling view.
Exercise 4: Material Master Maintenance
Exercise Objectives
After completing this exercise, you will be able to:
• Maintain material masters for configurable materials
Business Example
AA Computers is a PC manufacturing company. It manufactures various models of PCs. The company has decided to use SAP R/3 Enterprise to optimize its storage inventories and maintain every possible end-product variant. You are the Product Manager of the company. In the model for the PC configuration, you need to create the necessary material master records for the configurable materials. The PC and the header material of each assembly where you want to use object dependencies must be configurable. You need to create two master records, one for the PC and one for the Extras.
Task:
Create the following two materials with the material type that is defined for configurable materials, using the following data:
PC T-VPC## Extras T-VPZ##
1. Create T-VPC##, using Industry Sector M (Mechanical Eng.), Plant 1200
Sales Organization 1000, and Distribution Channel 10. Define the following views for material T-VPC##: Basic Data 1, 2
Classification
Sales Organization Data 1, 2 Sales Plant Data
MRP 1, 2, 3, 4 Work Scheduling Costing 1, 2
Maintain the following data for material T-VPC##: Basic Data 1, 2
Description: Configurable PC (Group ##) Base Unit of Measure: PC (pieces)
Classification Class Type: 300 Class: T_VPC_##
Note: Only assign the material to the class – do not assign any characteristic values. You can change the class type by choosing Extras. To continue from classification, choose the Next screen button or F8.
Sales Organization Data 1, 2 Delivering Plant: 1200 Tax Classification: 1 Item category group: 0002
(For both general and sales-specific item category group) Sales Plant Data
Transport Group: 0001 = On palettes Loading Group: 0002 = Forklift MRP 1, 2, 3, 4
MRP group: 25 = Make-to-order for configurable material MRP Type: PD = MRP
MRP Controller: 101 or 0## (Depends on database/client used) Lot size: EX = Lot-for-lot order quantity
Procurement type: X or E Scheduling Margin Key: 001
Costing 1, 2 Just accept the default values
2. Create T-VPZ## with Industry Sector M and material type KMAT.
→Use your PC, T-VPC## as a template to copy from. Do not maintain any classification view.
Plant 1200
Sales Organization 1000 Distribution Channel 10
Maintain the following views for material T-VPZ##: Basic Data 1, 2
Sales Organization Data 1, 2 Sales Plant Data
MRP 1, 2, 3, 4 Work Scheduling Costing 1, 2
For material T-VPZ##, use the same data as for T-VPC##, but without a classification view and with a new description:
Solution 4: Material Master Maintenance
Task:
Create the following two materials with the material type that is defined for configurable materials, using the following data:
PC T-VPC## Extras T-VPZ##
1. Create T-VPC##, using Industry Sector M (Mechanical Eng.), Plant 1200
Sales Organization 1000, and Distribution Channel 10. Define the following views for material T-VPC##: Basic Data 1, 2
Classification
Sales Organization Data 1, 2 Sales Plant Data
MRP 1, 2, 3, 4 Work Scheduling Costing 1, 2
Maintain the following data for material T-VPC##: Basic Data 1, 2
Description: Configurable PC (Group ##) Base Unit of Measure: PC (pieces)
Classification Class Type: 300 Class: T_VPC_##
Item category group: 0002
(For both general and sales-specific item category group) Sales Plant Data
Transport Group: 0001 = On palettes Loading Group: 0002 = Forklift MRP 1, 2, 3, 4
MRP group: 25 = Make-to-order for configurable material MRP Type: PD = MRP
MRP Controller: 101 or 0## (Depends on database/client used) Lot size: EX = Lot-for-lot order quantity
Procurement type: X or E Scheduling Margin Key: 001
No in-house production time (Acknowledge warning)
Strategy group: 25 = Make-to-Order for configurable material Availability check 02 = Individual requirements
Individual/Collective 1 = Individual requirements only Work Scheduling
Production scheduler: 101 Overall Profile: PP0001
Costing 1, 2 Just accept the default values a) Create material master records:
MMK1=
SAP Menu→Logistics→Production→Master Data→ Material Master→Material→Create (Special)→Configurable Material
or
User Menu→Material→Create (Special)→Configurable Material
Material: T-VPC##
Industry Sector:M = Mechanical Engineering→Enter => Select views: Basic Data 1, 2
Classification
Sales Organization Data 1, 2 Sales Plant Data
MRP 1, 2, 3, 4 Work Scheduling Costing 1, 2
Indicator “Create views selected“ Save as default values→Enter => Organizational levels:
Plant 1200
Sales organization 1000 Distribution channel 10
Save as default values→Enter Enter data as shown in the exercise.
Do not maintain any classification view. Plant 1200
Sales Organization 1000 Distribution Channel 10
Maintain the following views for material T-VPZ##: Basic Data 1, 2
Sales Organization Data 1, 2 Sales Plant Data
MRP 1, 2, 3, 4 Work Scheduling Costing 1, 2
For material T-VPZ##, use the same data as for T-VPC##, but without a classification view and with a new description:
A different Description: Extras for PC (Group ##) a) Create with template:
MMK1
Material: T-VPZ##
Industry Sector: M = Mechanical Engineering Copy from ... Material: T-VPC##!!! →Enter
=> Select views:No classification, but otherwise as above. → Enter
=> Organizational levels: Fill out Copy from column !!! Plant 1200
Sales organization 1000 Distribution channel 10
Save as default values→Enter
Enter data as shown in the exercise: in other words, only change: - Description
Lesson Summary
You should now be able to:
• Create a material master record, including control parameters for sales and Material Requirements Planning (MRP)
Lesson: Maintaining a Super BOM
Lesson Overview
This lesson explains how to maintain a super Bill of Material with class items and configurable assemblies.
Lesson Objectives
After completing this lesson, you will be able to:
• Maintain a super BOM without dependencies with class items and configurable assemblies
Business Example
ABC Motors is an automobile manufacturing company that manufactures various models of cars. The company is implementing variant
configuration solution to maintain all the possible end-product variants. You are the Product Manager of the company. To implement variant configuration solution, you have created the material master record. Now, you need to create the bill of material.
Overview of BOM
Figure 32: Super BOM
Definition: Bill of Material
A bill of material is a formally structured list for an object, and contains all the related objects, their description, their quantity, and their unit.
The BOM of a configurable material contains all the parts that are required for all possible variants of the material. Object dependencies are used to configure the BOM: only the parts that are required for a specific variant are selected. The BOM is exploded according to the characteristic values assigned.
You can also make manual changes to the BOM for a sales order, provided that the settings in the configuration profile allow this. You can, for example, delete or insert components. The BOM is then saved as an order BOM for the sales order.
You can change the BOM in the production order, as in production without variants.
Items in BOM
Figure 33: Class Item - Item Category K
You can enter a class in which materials or documents are classified as an item in a BOM. The class must have a class type that allows it to be used as a BOM item.
Figure 34: Non-Stock Item - Item Category N
You can create non-stock items both with and without a material master record. If you enter a non-stock item without entering a material number, you must enter a descriptive text and procurement data.
You enter the purchasing data for non-stock items with or without a material number, except materials with material type KMAT. The system uses the pricing data to determine the release strategy. The material group is required for generating a purchase requisition. The component is procured directly for the production order. Purchase requisitions are created automatically.
A non-stock item can also be a configurable material. In this example the EXTRAS is a place holder that contains the three components as pictured. The EXTRAS are selected when the sales order is configured, and must have the appropriate object dependencies.
Figure 35: Variable-Size Item - Item Category R
If you want to use one material number to represent different-sized pieces of a material, you assign the item category R.
On the Variable-Size Item Data detail screen, the system uses the sizes and formula you enter to immediately calculate the variable-size item quantity required.
Material requirements can be determined directly from the BOM explosion, without having to perform additional steps first.
You do not need to maintain a separate material master record for each section of the material that is cut to size.
Variable-size items are useful in variant configuration because you can use dependencies with reference characteristics to maintain variable-size item data.
Exercise 5: BOM Maintenance (Without
Dependencies)
Exercise Objectives
After completing this exercise, you will be able to: • Maintain super BOMs for configurable materials
Business Example
AA Computers is a PC manufacturing company. It manufactures various models of PCs. The company has decided to use SAP R/3 Enterprise to optimize its storage inventories and maintain every possible end-product variant. You are the Product Manager of the company. To model the PC and other configurable materials, you must create the super BOM. The BOM for the PC has multiple levels, so you need to create several BOMs in the system.
Task:
Create the two BOMs.
1. Create the two BOMs as shown:
in “PC - Customer Example (BOM Structure)“ Create the BOMs in:
Plant: 1200 and with:
Usage: Production = 1
The materials you require are in the following table.
All items are stock items, except for T-VPZ## and the class node for Colors. All items have quantity 1. Which item categories do the two items that are not stock items have?
You may want to copy from: T-VPC00 1200 1 and
T-VPZ00 1200 1, if you copy ask your instructor for details.
Description Material Number Configurable Personal Computer Bolt set Casing Tower Casing Minitower Casing Desktop CPU, Standard CPU, Medium CPU, Fast
Class Node for Color
Hard disk, small
Hard disk, medium
Hard disk, large
Hard disk, extra large
MS Access MS Word MS Excel MS Office Package CD drive, slow T-VPC## T-PCS T-PC21 T-PC22 T-PC23 T-CPU-1 T-CPU-2 T-CPU-3 (200) T_VPC_COLOR T-DISK-1 T-DISK-2 T-DISK-3 T-DISK-4 T-SW-10 T-SW-40 T-SW-20 T-SW-30
Configurable Extras for PC
Standard Keyboard
Mouse - Model: Standard
Modem 56600 bps
T-VPZ##
DPC1009
T-PZ1
Solution 5: BOM Maintenance (Without
Dependencies)
Task:
Create the two BOMs.
1. Create the two BOMs as shown:
in “PC - Customer Example (BOM Structure)“ Create the BOMs in:
Plant: 1200 and with:
Usage: Production = 1
The materials you require are in the following table.
All items are stock items, except for T-VPZ## and the class node for Colors. All items have quantity 1. Which item categories do the two items that are not stock items have?
You may want to copy from: T-VPC00 1200 1 and
Description Material Number Configurable Personal Computer Bolt set Casing Tower Casing Minitower Casing Desktop CPU, Standard CPU, Medium CPU, Fast
Class Node for Color
Hard disk, small
Hard disk, medium
Hard disk, large
Hard disk, extra large
MS Access MS Word MS Excel MS Office Package CD drive, slow CD drive, medium CD drive, fast
Speaker Set (2), 10 Watt
Speaker Set (2), 15 Watt
Speaker Set (2), 40 Watt
T-VPC## T-PCS T-PC21 T-PC22 T-PC23 T-CPU-1 T-CPU-2 T-CPU-3 (200) T_VPC_COLOR T-DISK-1 T-DISK-2 T-DISK-3 T-DISK-4 T-SW-10 T-SW-40 T-SW-20 T-SW-30 T-CD-1 T-CD-2 T-CD-3 T-SPEAKER-10 T-SPEAKER-15 T-SPEAKER-40
Configurable Extras for PC
Standard Keyboard
Mouse - Model: Standard
Modem 56600 bps
T-VPZ##
DPC1009
T-PZ1
DPC9026
a) Create a bill of material: Option 1: (without template): CS01=
SAP Menu→Logistics→Production→Master Data→Bills of Material→Bill of Material→Material BOM→Create or
User Menu→Bill of Material→Material BOM→Create Material: T-VPC##
Plant: 1200
BOM Usage: 1 = Production Enter items according to the list. Bill of Material 2:
CS01
Material: T-VPZ## Plant: 1200
BOM Usage: 1 = Production Enter items according to the list.
=> Copy from Material: T-VPC00 Plant: 1200
BOM Usage: 1 = Production
→Enter
→Select all = Ctrl + F3
→Copy = F5
Change item 90 to T-VPZ##.
2. Copy bill of material T-VPZ00 to T-VPZ## in the same way. CS01
Material: T-VPZ## Plant: 1200
BOM Usage: 1 = Production Enter items according to the list.
3. Option 2: (With template, with engineering workbench): CEWB =
SAP Menu→Logistics→Production→Master Data→ Engineering Workbench
or
User Menu→Engineering Workbench => Select EWB working area:
S_ALLES Focus BOM Header - All
→Enter
Pushbutton: Additional Selection Criteria Tab page: BOM Header
Material: T-VPC00 and T-VPZ00 Use multiple selection and copy. Plant: 1200
→Execute: Load BOMs and Task Lists => BOM Headers Overview
Use the pushbutton Set/Reset Data in Context to reset the context area.
Select the line containing T-VPC00. →Copy = Shift + F11 => Dialog box: EWB: Process Using→Enter
=> Dialog box: EWB: Copy - Target Data T-VPC##1200 1 Set ’Multilevel Copy’ indicator
→Copy Range Here, select:
- All indicators for routings - Component Assignment
- All indicators for bills of material
- No object dependencies and no classification Execute = F8
Copy = F8
Select new line only.
→Bills of Material→Items
Overwrite extras with a separate material T-VPZ##. (You may want to check the routing:
→Task Lists→ Headers=> Two headers→Task Lists → Operations=> Operations for first task list with dependencies, for second task list without dependencies.
→Bills of Material→BOM Headers
Use the pushbutton Set/Reset Data in Context to reset the context area.
Select the line containing T-VPZ00 only: Copy = Shift + F11
-No object dependencies and no classification -No Component Assignment
-No indicators for routings (except those that cannot be deleted) Execute
Copy Save
Lesson Summary
You should now be able to:
• Maintain a super BOM without dependencies with class items and configurable assemblies
Lesson: Maintaining Task Lists
Lesson Overview
This lesson describes how to maintain a task list and routing with additional sequences, suboperations, and Production Resources/Tools (PRTs).
Lesson Objectives
After completing this lesson, you will be able to:
• Maintain task lists and routings without dependencies with additional sequences, suboperations, and Production Resources/Tools (PRTs)
Business Example
ABC Motors is an automobile manufacturing company. It manufactures various models of cars. The company is implementing variant
configuration solution to maintain end-product variants. As the Product Manager of the company, you have created the material master record and the bill of material. Now, you need to create a task list and routing. These are used to represent all variants of the product.
Overview of Task Lists
Figure 36: Super Task List
A task list is a list that describes the process for producing a material or for performing a service. The task list contains all the operations, suboperations, and Production Resources/Tools (PRTs) that are required to produce the material.
The task list or routing for a configurable material contains all the sequences, operations, suboperations, and PRT assignments that are required to produce all possible variants of the material. You then assign dependencies to the operations, sequences, and PRTs in routings for configurable materials.
The operations for a specific variant are selected by object dependencies. The routing is exploded according to the characteristic values you assign. You can create a routing by copying the configuration simulation. You can do this for a specific sales order.
Using Task Lists
Figure 37: Task List