Click Spool parameters for user to reach this screen
Double click on the User Name to the Print List and Printer Name for each user.
The control are Plant and User Login name.
Listed in the Spool parameters for user are all the user names that are allowed to print the shop papers.
Double click on the user name that are allowed to print the shop papers.
Here you tick on the Print column the Print Shop Paper Layout that will be used. You can specify the default printer if you want. To print immediately, just tick the Immed.
column.
Click Reference order types to configure the RefOrdType for the Production Order.
Click Forms to configure any new SAPscripts that you may have.
Click on Print programs to configure any new Report name you may have.
Click on Printer Specification and configure how you want to control the Output device.
Click on Flow control for transactions to configure how you want to process the printing.
Preparing the Initial Implementation of the PP Shop Floor Control Module Before the live-implementation of the SAP system, there will be a cut-off day to turn-on from the OLD to the NEW SAP system. The PP Shop Floor Control module is one of the most important module although it belongs to the last process flow because the
Production Floor will based on the Production Order Generated to produce the Finished Goods for the Customer.
As a PP consultant, you have to inform the users that they have to get those CRITICAL data into the system before going live.
Work Center Master Bills of Materials Master Routing Master
Remember that when the user create a new Production Order, the system will READ from the BOM and Routing Master.
Take note that the Master data can be input into the SAP system even BEFORE going live as long as there are no transaction postings such as Production Confirmation which will impact the Financial figures.
Normally, in an on-going business, there will be existing OPEN non-SAP Production Order. You must let the EVERYONE know that as the days come nearer to the
implementation date, they must try to keep the OPEN non-SAP Production Order quantity just enough to be CLOSE before going live. For e.g. if the ACTUAL production quantity is 10,000 and they estimate that they can only complete 3,000 by the time of the
Implementation, they should only CREATE the production order to produce 3,000 only.
The other 7,000 should only be created AFTER going live on the NEW SAP system.
How about those Process Incomplete Production Order?
In a manufacturing environment, Division of Labor means Jobs are separated in stages as to achieve maximum Productivity. There are certain cases of Incomplete Production Process where 3,000 was completed in Process 1. When it reaches Process 2, only 1,000 can be completed. In this case, the user still have to close the non-SAP Production Order and RE-OPEN a new SAP Production Order for the remaining 2,000 for Process 2.
They have to take note of the difference either on the non-SAP Production Order or as a Text note on the SAP Production Order.
Production Floor users are also recommended to return all those additional raw materials to the Inventory Stores. This will aid in the accuracy of the Physical Stock count. They can then re-draw the raw materials after going-live.
Static versus dynamic data conversion
In general, data could be classified as begin either static or dynamic data.
Static data includes items that are relatively stable such as vendor master, material master, BOM, routing, work centers, customer master, price agreement, material group, activity prices, cost centers etc.
Dynamic data includes items such as inventory balances, A/R balances, A/P balances, GL balances, Open Production Orders, Open Sales Orders, Open Purchase Orders and Planned Independent Requirements.
In general, we will have lots of time to convert the static data but insufficient time to rush the dynamic data into the system. This is because dynamic data must be converted with a clear cut-off date. This means that the balances must be that of the same point in time in order to ensure the integrity of data.
Where the volume of data in relation to the number of end users is high, we will consider automating the conversion, provided that data is available from the old system.
If the volume is low or if data is not available from the present system, users should key the data directly into SAP. This approach has an added and important benefit of training the end users in the operation of the SAP system.
A Sample Note to users regarding the Uncompleted Production Orders This is the most complex area for conversion. We must take the following step to minimize the number of uncompleted production orders.
Three weeks before the cut-over date, all un-started and newly created production orders will be marked with a special color code. A bold instruction “Do not record component issue and labor cost until completion” will be stamped on these production orders.
We will withhold the recording of material issues and production activities in the Old System and related systems if the production orders are color coded.
If the production orders are completed and need to be received into stores before the cut-over date, we will then enter the component issue and labor activity to the
production orders before the goods receipts of the finished product.
If the production orders are not completed before the cut-over date, we will manually create the production orders in SAP and enter the confirmation in SAP. Material issue will be performed in the SAP after the cut-over date.
If stock take of raw material take place on the cut-over date, we must take care to add back the raw materials which issue has been withheld.
For the purpose of general ledger, we will manually compute an accrual and reversal entry to ensure that proper cut-off are observed for accounting purposes. The entry to put through to FY19XX in the old GL system prior to its conversion is to Dr WIP, Cr Raw Material (for the material component) and to Dr WIP Cr Manufacturing cost for the labor component. The reversal entry for FY19YY should be Dr Raw Material Cr WIP (for the raw material component) and Dr WIP Change account Cr WIP for the labor component.
Appendix A: The Production Order Status Business Process Flow
The Production Order Status refer to the business process flow of the current Production Order. This is a way for the system to control the different activities of the user on the Production Order.
An example of a Production Order Business Process Flow:
1. A Planner User convert the Plan Order to a Production Order, the initial status will be CRTD. The status CRTD means that this order is not firm for Production.
2. The Production User will not be able to Print Out the Production Order until the Planner User Release it which will change the status to REL.
3. The Planner User Release the Production Order (CO02 – Functions – Release) and the Production User will be able to print out the Production Order (CO04N) for actual Production. After printing the Shop Floor Paper, the order will include the status PRT to inform the user that this order have been printed.
4. Actual Production started and upon completion the Production User will input the Production information which they have collected and written on the Shop Floor Paper into the SAP system. This is called Production Confirmation (CO11). An Order which is partially completed, will include the status PCNF. Once it is Fully completed, the status will change to CNF.
5. A fully completed production order means that the materials has turned into a Finished Product which is really to be ship to the Customer. The Delivery User will receive the fully completed Production Order (which is the Finished Product - MB31) into his warehouse and he can then delivered it to the customer. Finally, the status will include DLV which means that the whole Production Order process have been completed.
6. In cases where the Production Order was stopped due to the Customer Order
Cancellation, the Production User can closed the Order by setting the status to TECH (CO02 – Functions – Restrict Processing – Technically Complete).
A Sample of the SAP Production Order Screen – CO01/CO02
Appendix B: How to make enquiry on Open Production Orders?
Transaction : COOIS
SAP Menu Path : Logistics – Production – Production Control – Information System - Production Order Information System
The default enquiry is by Order Headers. You can make enquiry by Operations if you want to by changing the List Profile. To list the Open Production Orders, make used of the System Status and exclude all status with CNF (Confirmed) and DLV (Delivered).
Appendix C: What is Backflushing and Where is the Indicator Set?
In SAP context, Backflushing means to consumed those Materials that have been used during the course of the Manufacturing Process. To produce something, raw materials may be required. With reference to the Bill of Materials, the Purchaser will buy those materials based on the requirement prompt by the SAP MRP system. Upon finishing the Manufacturing Process, raw materials will be used up to produced the Finished Goods for the Customer.
The Planner will determined at which Production Operation will this components be consumed and set the Backflushing indicator accordingly.
To set the Backflushed Indicator:
Transaction : CA01/CA02
SAP Menu Path : Logistics – Production – Master Data – Routings – Routings – Standard Routings – Create/Change
Assuming that you have built the BOM and input the Work Center for each Operations.
This is the first screen when you enter CA02. Now, click the CompAlloc button.
At the CompAlloc screen, you will see the Backflushing Indicator. A tick will indicate that the Components will be deducted when the Production User do the Production
Confirmation. If the Backflushed Indicator is grey, this mean that Backflushing have not been assigned. To assigned it, click the New assignment button.
A New assignment screen will pop-up. Just input the Operations that you want the Components to be Backflushed. When the Planner create a Production Order, the
system will read the Routing Master data and copied all this information to the Production Order.
Ultimately, it still the Production Order will decide which Operation will the Components be Backflushed.
At the First Screen in CO01/CO02 – Production Order Create/Change, click the Components Overview button.
The Backflushed Indicator will be copied from the Routing but the Planner still can changed it in the Production Order.
Checking the Backflushing Goods Movement
Whenever the user post a confirmation with CO11N, the backflushing components goods movement will be tied to the production order. You can check them with Tcode
CO02/CO03 by clicking the menu Goto – Documented goods movements.