SAP - TSCM40

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TSCM40_I

Planning / Manufacturing I

SAP ERP - Production

Date Training Center Instructors Education Website

Instructor Handbook

Course Version: 95

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About This Handbook

This handbook is intended to complement the instructor-led presentation of this course, and serve as a source of reference. It is not suitable for self-study.

Typographic Conventions

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Course Overview

The course TSCM40 teaches you how to work with master data (course week 1) and production planning (course week 2) in SAP ECC.

The course material therefore consists of two course books: TSCM40_I and TSCM40_II.

This course book TSCM40_I only deals with the content of the first week of TSCM40. The second week is covered by the course book TSCM40_II.

Target Audience

This course is intended for the following audiences:

• Application consultants responsible for the implementation of planning as part of the SAP Business Suite in SAP ERP.

Course Prerequisites

Required Knowledge

• SAP125 – SAP Navigation 2005 (e-learning) • TERP01 – SAP ERP: Introduction (e-learning)

• TERP02 – SAP ERP: Introduction to SAP NetWeaver (e-learning) • TERP51 – SAP ERP: Introduction to Processes in Material Planning

(e-learning)

• TERP52 – SAP ERP: Introduction to Processes in Manufacturing Execution (e-learning)

Recommended Knowledge

• No additional knowledge required

Course Duration Details

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Storage Locations 20 Minutes

MRP Areas 15 Minutes

Unit 4: Material Masters

Overview of the Material Master 30 Minutes Creating a Material Master 45 Minutes Exercise 1: Creating Material Masters 40 Minutes Classification of the Material Master 30 Minutes Exercise 2: Material Classification 15 Minutes Managing the Material Master 45 Minutes Exercise 3: Managing Material Masters 20 Minutes Unit 5: Bills of Material

Overview of the Bill of Material 45 Minutes Exercise 4: BOM Basics 20 Minutes Managing Bills of Material 45 Minutes Exercise 5: Changing Bills of Material 40 Minutes

BOM Reporting 20 Minutes

Exercise 6: Multilevel BOM Reporting 15 Minutes Unit 6: Modeling the Manufacturing Process

Modeling Manufacturing 30 Minutes Basic Work Center Data and Defaults 30 Minutes Exercise 7: Create a Work Center 15 Minutes Capacities in the Work Center 45 Minutes Exercise 8: Capacities in the Work Center 15 Minutes Integrating Costing with the Work Center 20 Minutes Unit 7: Task Lists

Overview of the Task List 20 Minutes Exercise 9: Create a Simple Routing 20 Minutes Creating a Routing and Material Assignment 30 Minutes

Exercise 10: Material Assignment and Component

Allocation 15 Minutes

Suboperations and User-Defined Fields 25 Minutes Exercise 11: Suboperations for Material-Specific

Capacity Constraints 10 Minutes Reporting and Mass Changes 15 Minutes Exercise 12: Task List Changes with ECM 20 Minutes Unit 8: Advanced Bill of Material Functions

Phantom Assemblies 30 Minutes

Co-Products and By-Products 15 Minutes Exercise 13: Co-Products in Production Orders 20 Minutes Discontinuation and Substitute Parts in the Bill of

Material 30 Minutes

Exercise 14: Substitute Items in Production Orders 20 Minutes Multiple and Variant BOMS 40 Minutes

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TSCM40_I Course Overview

Exercise 15: Multiple/Alternative Bills of Material 15 Minutes Exercise 16: Variant BOMs 20 Minutes Mass Changes and the Product Structure Browser 20 Minutes

Exercise 17: Mass Changes and the Product

Structure Browser 10 Minutes Unit 9: Advanced Routing Functions

Modeling Complex and Flexible Manufacturing

Processes 20 Minutes

Exercise 18: Creating Alternative and Parallel

Sequences 20 Minutes

Modeling Alternative Manufacturing Processes 20 Minutes Exercise 19: Creating Alternative Routings and

Production Versions 30 Minutes Reference Operation Sets 20 Minutes Exercise 20: Reference Operation Sets 20 Minutes Lead Time Scheduling and Material Master Updates 30 Minutes Exercise 21: Scheduling 20 Minutes Time Components, Reduction Possibilities in the

Routing 30 Minutes

Exercise 22: Time Elements of the Operation in

Scheduling 30 Minutes

Trigger Points in the Routing 30 Minutes Scrap and Its Effects 25 Minutes Exercise 23: Scrap in Production 20 Minutes Production Resources/Tools 20 Minutes Exercise 24: Creating and Assigning PRTs 10 Minutes Unit 10: Alternative User Interfaces

Structure of the Engineering Workbench 40 Minutes Navigating in the Engineering Workbench 45 Minutes Exercise 25: Navigating in the EWB 30 Minutes Exercise 26: Navigating in the EWB II 35 Minutes Engineering Workbench Work Areas 20 Minutes Exercise 27: Create a Work Area 20 Minutes Introduction to the PLM Web User Interface 30 Minutes Exercise 28: Using the PLM Web User Interface 20 Minutes

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Configuring the Routing 45 Minutes

Course Goals

This course will prepare you to:

• Understand the general handling of logistics master data in SAP ECC • Understand and describe the positioning, integration, and functions of the

planning area within the SAP ERP application

Course Objectives

After completing this course, you will be able to:

• Use the relevant master data elements for the modelling of planning and production processes

• Evaluate, describe, and implement the options provided by SAP-ERP-based planning

SAP Software Component Information

The information in this course pertains to the following SAP Software Components and releases:

• SAP ERP Central Component 5.0 • SAP ERP Central Component 6.05

Important Information

It is strongly recommended to check necessary information published on the SAP Service Market Place. All information essential for course preparation like instructor guides, system setup guides, trouble shooting guides, logon information, and so on, you will find under the alias /curr-info (http://service.sap.com/curr-info).

In case you cannot access this site please ask the responsible education coordinator (the sender of this document) to make the relevant information available to you.

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Unit 1

1

Course Overview

Welcome the participants to the first week of the course and introduce yourself and briefly the overall course content and objectives. Familiarize the participants with the course schedule. Ask the participants to introduce themselves.

Unit Overview

The academy course TSCM40 operates exclusively within SAP ECC as far as content, demonstrations, and exercises are concerned, dealing with the master data background and production planning process in the system. The course builds on the basics contained in the according e-learning sessions.

As an introduction, the course contents are outlined.

Unit Objectives

After completing this unit, you will be able to: • Give an overview of the scope of the training

Unit Contents

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Lesson:

2

Academy Overview

Lesson Duration: 10 Minutes

Lesson Overview

This lesson provides an overview of the training required for the Application Associate Planning & Manufacturing with SAP ERP 6.0.

Lesson Objectives

After completing this lesson, you will be able to: • Give an overview of the scope of the training

Provide the participants with a brief overview of the academy course. Refer to the e-learning courses that the participants should already have attended.

Business Example

Basic Training

The training courses TSCM40 (Planning/Manufacturing I) and TSCM42 (Planning/Manufacturing II (including case study)) provide the participants with knowledge of the business processes of planning and manufacturing in a basic training geared towards manufacturing companies.

In the training course TSCM40 (Planning/Manufacturing I), you learn about the master data required for production (material masters, bills of material, work centers, routings, etc.), including master data management, as well as about the concepts and business processes of selected planning areas. The course deals with the processes of production planning using material requirements planning (ERP-PP-MRP module), as well as the different planning strategies for creating a master plan. The course also demonstrates evaluation methods for evaluating the planning results.

The follow-up training course TSCM42 (Planning/Manufacturing II (including case study)) teaches you the different options for controlling production. This includes order-based production with production orders or process orders, repetitive manufacturing, and Kanban. These options provide effective support for the complete manufacturing process including the process steps of material staging, sequencing, creation of shop floor papers, confirmation, goods receipt, and settlement of production activities. The focus is set on production order management. An overview is provided of the other options named above.

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TSCM40_I Lesson: Academy Overview

Moreover, the training course also contains a summary of capacity planning as well as a case study. The latter allows you to apply the knowledge you have acquired by configuring specified integrated business processes. The training course ends with an exam (certification C_TSCM42_65).

The following diagram provides an overview of the scope of the training.

Figure 1: Consultant Profile Application Associate - Planning & Manufacturing with SAP ERP 6.0: Basic Training

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Solution Academy Training Course Content TSCM40 (Planning/Manufacturing

I)

5 days PLM114 (Basic Data)

5 days SCM240 (Production Planning (ERP))

TSCM42 (Planning/Manufacturing II (incl. Case Study))

4.5 days SCM310 (Production Orders) 0.5 days KANBAN from SCM300 (Production Overview)

1 day from SCM365 (Capacity Planning (ERP))

1 day Repetitive Manufacturing and Process Manufacturing from SCM300 (Production Overview)

2.5 days Integrated Case Study (academy only!)

3 hours Certification Exam C_TSCM42_65

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TSCM40_I Lesson: Academy Overview

Facilitated Discussion

Optional

Discussion Questions

Use the following questions to engage the participants in the discussion. Feel free to use your own additional questions.

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Lesson Summary

You should now be able to:

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TSCM40_I Unit Summary

Unit Summary

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Unit 2

7

Overview of Master Data for Product

Management and Manufacturing

This unit is designed as an introduction to the use of master data in

production planning and execution in SAP ERP. Participants might have taken SCM100/SCM300 or SCM130 to have a more detailed overview of the Planning and execution functions in SAP ERP. This section is designed as a refresher for those participants and enlighten participants who have not taken the necessary prerequisites.

Unit Overview

This unit introduces you to how master data will be used in supporting the SAP ERP production planning and execution process. The different master data and organizational data are discused at a summary level. Each object will be covered in more detail in following lessons.

Unit Objectives

After completing this unit, you will be able to:

• Describe the types of data used in modeling and executing manufacturing in SAP ERP

• Identify the production planning organizational units (configuration) • Identify the procurement organizational units

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Lesson: Use of Organizational Data and Master Data in Production ... 20

Demonstration: Organizational Structures in SAP ERP... 25

Demonstration: Views and Fields in the Material Master ... 28

Demonstration: BOMs ... 29

Demonstration: Work Centers ... 31

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TSCM40_I Lesson: Types of Data in SAP ERP

Lesson:

8

Types of Data in SAP ERP

Lesson Overview

In this lesson we will discuss the different types of data that users and project team members will deal with during an implementation and after go live.

Lesson Objectives

After completing this lesson, you will be able to:

This section is designed for true beginners. If you have an experienced class, gloss over the material at high level. This will be an introduction to configuration.

Business Example

Your company, Precision Pumps, has just purchased SAP ERP to efficiently run your business. As a member of the project team in a company that manufactures pumps, you are responsible for the introduction of basic data for manufacturing. The defined basic data will be used in the procurement, scheduling, manufacturing, and costing of all components and products necessary for the manufacturing of pumps. You must introduce the basic concepts of configuration in SAP ERP, as well as master data and organization data.

Data Types in SAP ERP

When dealing with a software system as robust as SAP ERP, you need to have perspective on how your business will be modeled in a software environment. In SAP ERP, users will have essentially three types of data:

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Figure 2: Configuration in SAP ERP

During an implementation, the SAP ERP landscape will typically consist of three servers: DEV (development), QA (quality assurance), and PROD (production). Each server may have several clients. The DEV server is where a sandbox client will exist, as well as the golden client, where the final configuration resides. During the project, team members will try different iterations of configuration in the sandbox client and test the results. If the results meet the organizations requirements, they are configured again in the golden client. From there, the Basis team moves it to the QA server for further evaluation. The Basis team will us a tool called the Change and Transport System (CTS). This allows them to track the configuration changes from DEV to QA, and QA to PROD.

Once the configuration changes are moved to the QA server, integration testing will take place within the PP module and within the other applications in SAP ERP, such as materials management (MM) and Sales and Distribution (SD), for example. Once fully tested in the QA system, the configuration will be transferred to PROD, or the production server/client.

Demonstration: Configuration in SAP ERP

Purpose

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TSCM40_I Lesson: Types of Data in SAP ERP System Data System: Client: User ID: Password: Set up instructions:

1. Show students Transaction code SPRO. Do not bother to show menu path as it seems to change for every new release.

2. Select Reference IMG

3. follow menu path : Production → Basic Data → Bill of Material → Control

Data for Bill of Material → Define Default Parameters

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10

Configuring SAP ERP

1. Enter transaction code SPRO. 2. Select Reference IMG.

3. Choose Production → Basic Data → Bill of Material → Control Data for

Bill of Material → Define Default Parameters.

Master Data in SAP ERP

Configuration will be the foundation upon which most master data will be built. Master data is often referred to as “slowly changing” data. This means the data of a particular object does not change all the time, but often several times a year.

Figure 3: Master Data

Master data in SAP ERP is a centralized function. This means that the data is be intended to be stored once and replication is to be avoided. The master data that will be used for production planning in SAP ERP is as follows:

• Material masters • Bills of material • Work centers • Task lists/routings • Cost centers

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Business users will be limited to creating, changing, or displaying data based on their role within the organization. During implementations, each business must determine how the Product Lifecycle Management (PLM) process within SAP ERP will integrate with their specific business processes.

As organizations change, so must the master data to support the business; this needs to be modeled properly within the SAP ERP environment.

Demonstration: Production Planning Master Data

Purpose System Data System: Client: User ID: Password: Set up instructions:

1. Show users the menu paths they will be using over the next several days. 2. Follow Menu path : Logistics → Production → Master Data

3. Point out the folders for the material master, Bill of material, Work Center and Routing.

Transactional Data

Every day, businesses perform tens of thousands of transactions that make the business function. Some transactions are directly related to outside events with customers or suppliers. Other events are internal to the business and affect the interaction between departments within a business or division.

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Figure 4: Transactional Data

Within SAP ERP, all transactional data is related to some form of master data or configuration data. In the world of production planning, you will be executing planning runs that will be generating replenishment suggestions, generating production execution directions, or executing production confirmations. In SAP ERP production planning, all transactional data typically revolves around the material master, bill of material, or routing.

In this class you will learn how master data works; however you may be asked to analyze how it works in conjunction with day-to-day business events or transactions, such as a production order.

Demonstration: Transactional Data

Purpose

Demonstrate creating a production order and the need for master data

System Data System: Client: User ID: Password: Set up instructions:

1. Follow menu path: Logistics → Production → Production Control → Order

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2. Enter material T-F200, plant 1000, order type PP01. Select Enter

3. Enter 10 pcs and enter a finish date of on month from today. Select Enter 4. Show customers the Material master , Bill of Material, Routing and work

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Facilitated Discussion

Discussion Questions

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Lesson Summary

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Lesson:

13

Use of Organizational Data and Master Data in

Production

Lesson Overview

In this lesson you will be exposed to organizational data and its potential impact on production planning in SAP ERP.

Lesson Objectives

• Identify the Sales and Distribution organizational units • Identify the production planning master data objects

This lesson is designed for new customers that have never worked SAP ERP or production planning. If class participants are knowledgeable in SAP ERP use this as an overview and move through the material quickly.

Note: We have included information about other application

organizational levels as students will come across the objects within the PP master data. It is collateral information only. If they wish to know more about SD organizational structures suggest SCM600. If they wish to know more about MM organizational Structures suggest SCM500.

Business Example

As a member of the project team, you must understand how organizational structures, production planning, and master data are used to develop an organizational plan to support existing and future business.

Organizational Objects in Production Planning

The foundation of the SAP ERP system is the organizational structure that will be configured at the early stages of your company’s implementation of the software. All other configuration or master data will be built on top of the organizational structures.

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TSCM40_I Lesson: Use of Organizational Data and Master Data in Production

Figure 5: Organizational Structure

To better understand the structure, you must familiarize your self with several definitions:

Client

The client is a unit within an SAP ERP system that is self-contained both in legal and organizational terms, and in terms of data, with separate master records and an independent set of tables. From a business viewpoint, the client represents a corporate group, for example.

The client is the highest hierarchical level in the SAP ERP system. Specifications or data that you make and enter at this level apply to all company codes and all other organizational units. Therefor, you do not have to enter the specifications and data in the system at client level more than once. This ensures a uniform data status.

Access authorization is assigned on a client-specific basis. A user master record must be created for every user in the client in which he or she wishes to work. If the Client field has not been prepopulated, each user must specify a client key when logging on to an SAP ERP client. The client key is uniquely defined in the system and is a three-digit number. In this way,

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Company code

A company code is the smallest organizational unit of external accounting for which a complete, self-contained bookkeeping system can be replicated. This includes the entry of all events that require posting to the accounts and the creation of a complete audit trail for balance sheets and profit-and-loss statements. A company code represents an independent unit producing its own balance sheet, for example, a company within a corporate group (client). You can set up several company codes in one client in order to keep separate sets of financial books. You can use a special Customizing function to copy a company code. In the process, company-code-dependent specifications are adopted for your new company code.

A company code is defined in the system by means of a four-character alphanumeric key that is unique in the client.

Plant

The plant is an organizational unit within logistics that subdivides an enterprise from the viewpoints of production, procurement, and materials planning.

Storage Location

The storage location is an organizational unit that facilitates the

differentiation of stocks of materials within a plant. Inventory management on a quantity basis is carried out in the plant at storage-location level. The physical inventory is also carried out at this level.

A storage location is defined by means of a four-character alphanumeric key that is unique in the plant.

Organizational units are tightly linked to each other to quickly process the relevant data for a business area. For example:

Plant 1000 is assigned to company code 1000 Company code 1000 is assigned to controlling area 1000 Therefore, whenever a transaction involving cost occurs in plant 1000, the relevant records in controlling area 1000 are automatically updated. The valuation area is the organizational level at which material quantities and values are managed. It is essential for product costing that a valuation area exists for each plant.

Within each valuation level, you can differentiate between values and quantities for valuation (in-house production and external procurement) by using different valuation types. In Customizing for materials management (define valuation type), balance sheet valuation is set up at company-code or valuation-area level.

Selection of valuation-area level automatically causes the creation of a valuation area for each plant. To use product costing and order costing, inventory must be valuated at plant level.

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Purchasing Organization

Outside of production planning, other areas of the SAP ERP system need additional configuration to support their specific functional needs. In addition to the client and company code requirements, purchasing requires an additional organizational structure.

Figure 6: Purchase Organization

A purchasing group is a key for a buyer or a group of buyers who are responsible for certain purchasing activities. Internally, the purchasing group is responsible for the procurement of a material or class of materials. Externally, it is the principal channel for an enterprise’s dealings with its vendors.

Note: The purchasing group is not assigned to other units of the enterprise structure in SAP ERP.

Purchasing groups are not defined in Customizing for the enterprise structure, but in Customizing by choosing Materials Management → Purchasing → Create

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You can incorporate purchasing into the company structure by assigning the purchasing organization to a company code and to plants. This means that you can take into account whether purchasing is organized on a centralized or decentralized basis in your company. You can have a combination of these two organizational forms.

You can assign several purchasing organizations to one company code. However, a certain purchasing organization can only belong to one company code. You can decide not to assign the purchasing organization to a company code (cross-company-code purchasing). There is an m:n relationship between purchasing organizations and plants. In other words, you can assign several plants to one purchasing organization, and one plant to several purchasing organizations.

Sales Organization

Similar to the purchasing side of an organization, the group responsible for sales has additional unique business requirements.

Figure 7: Sales Organization

The sales organization is responsible for selling and distributing goods and services. It is liable for the products sold and responsible for a customer’s rights of recourse. The sales organization can be used to represent a regional, national, or international subdivision of a marketplace in which products are sold.

A sales organization is uniquely assigned to a company code, however a company code may have more than one sales organization assigned to it. If the Sales and Distribution module is used, at least one sales organization must be defined. The sales organization is the highest summation level in sales statistics. Customer master data will be created for each sales organization. Documents created throughout the Sales and Distribution process (order, delivery, and billing document) will belong to a sales organization.

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A distribution channel is a means through which saleable materials or services reach the customer. A distribution channel is assigned to a sales organization. A sales organization may have more than one distribution channel assigned to it. If the Sales and Distribution module is used, at least one distribution channel must be defined and assigned to a sales organization.

A distribution channel allows customers to be treated differently depending on the channel they are assigned to. For example, a customer assigned to a wholesale distribution channel may receive preferred pricing compared to a retail distribution channel customer.

A sales organization can have several divisions assigned to it, but must have at least one division. A division is used to group materials and services. A division can represent a product group or product line, which allows:

• Restricted price agreements to a certain division • Statistical analysis by division

A sales area is a unique and allowable combination of a sales organization, distribution channel, and division. Each Sales and Distribution document is assigned to exactly one sales area. This assignment cannot be changed. A sales area can belong to only one company code. This relationship is created by the assignment of the sales organization to the company code in Customizing. The shipping point is the organizational element that manages your shipping activities. Each outbound delivery is processed at a shipping point.

A shipping point can be a physical location, for example, a loading dock, a mail room, or a railroad depot. It can also be a logical location, for example, a group of employees responsible for processing next-day deliveries or less-than-truckload orders.

Shipping points are assigned to plants. A shipping point should have physical proximity to the plant to which it is assigned. More than one shipping point can be assigned to a plant. Several plants can also have a shared shipping point assigned to them, for example, several plants in same physical proximity sharing the same railroad depot.

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Password:

Set up instructions:

1. Follow Menu Path: SPRO → Enterprise Structure → Assignment →

Logistics-General → Assign Plant to Company Code →

2. Assign Business Area to Plant/Valuation Area...

3. SPRO → Enterprise Structure → Assignment → Sales and Distribution → Assign Sales Org to Company Code...

4. SPRO → Enterprise Structure → Assignment → Materials Management → Assign Purchasing Org to Company Code...

Master Data Objects in Production Planning

Once your company has established an organization structure, the different business areas can proceed with developing the application-specific master data to activate the necessary functionality required to run the day-to-day activities of your business.

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Within the PP application, several pieces of master data are required to carry out planning and execution functionality. The following master data objects are required to initiate planning and execution functions in SAP ERP:

• Material master • Bill of material • Work center • Routing/task list

Material Masters

Material Master Record: Definition

The material master contains information on the materials that a company constructs, procures, manufactures, stores, and sells. The information is stored in a database that is a central source of data on materials. The material master record integrates data from different areas of a company.

Figure 9: Material Masters in SAP ERP

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Demonstration: Views and Fields in the Material

Master

Purpose

Demonstrate the material master

System Data

System:

Client: 8##

User ID: Password:

Set up instructions: P-100 in plant 1000

1. Show material P-100 in plant 1000. Follow menu Path: Logistics →

Production → Master Data → Material Master → Material → Change → Immediately

Bills of Material

A bill of material (BOM) is a complete, formally structured list of the components that make up a product or assembly. The list contains a description and object number for each component, together with the quantity and unit of measure. Bills of material can exist at the plant and/or client level. The header and components all contain validity dates that can be affected using Engineering Change Management.

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Figure 10: Bills of Material In SAP ERP

Bills of material will be integrated with the material master and can be used in conjunction with routing to schedule a more precise usage point. These BOMs are used in material requirements planning, production, procurement, and product costing.

A BOM consists of header material and BOM items (components). The base quantity in the header material specifies the finished production quantity on which the component quantities are based. BOM items indicate individual parts and assemblies, which are identified by their material numbers.

BOMs are single level. A BOM item can also contain components, so that multi-level production can be described by the single-level BOMs from the finished product, assemblies, or assemblies of the assemblies (and so on). In addition to stock items, which flow into the finished product, a BOM can also contain documents or text items.

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Password:

1. In the BOM P-100 show the BOM header and the components with their item categories.

Show material P-100 in plant 1000. Follow menu Path: Logistics →

Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change

Work Centers

A work center is a location that defines when and where production resources are required according to order requirements. In different companies, work centers are also called machine, labor, or capacity centers.

Figure 11: Work Centers in SAP ERP

Work centers can be defined as individual or multiple machines, people, tools, and so on. Work centers are used in routings (routings, standard networks, inspection plans, maintenance task lists, and rough-cut planning profiles) and in orders.

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Demonstration: Work Centers

Purpose

Where to find work centers.

System Data System: Client: 8## User ID: Password: Set up instructions:

1. Show Work Center 1310 in plant 1000. Follow menu Path: Logistics →

Production → Master Data → Work Center → Work Center → Change

Task Lists and Routings

A routing defines operations and the sequence in which they are carried out. The following is also defined in the routing:

• Where the work is to be done • How long the work should take

• What materials are needed for each operation • What tools and fixtures are required

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Figure 12: Routings in SAP ERP

A routing shows operations in a sequence and acts as a template for production orders. Each step defines the work center in which specific work will be accomplished. The planned time for each operation is stored in the routing as a standard value.

These standard values are the basis for: • Lead time scheduling

• Product costing • Capacity planning

Demonstration: Routings

Purpose System Data System: Client: User ID: Password: Set up instructions:

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1. Show Routing P-100 in plant 1000. Follow menu Path: Logistics →

Production → Master Data → Routings → Routings→ Standard Routing → Change

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Facilitated Discussion

Perform overview of lesson.

Discussion Questions

• What are the PP-relevant organizational elements?

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Lesson Summary

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Unit Summary

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Unit 3

27

Organizational Data in Supply Chain

Management

In this lesson you will introduce the participants to the concepts of configuration and the IMG. This lesson is designed to be as informative to new users and a refresher for experienced users.

Unit Overview

In this unit, you will be introduced to how your company’s organization structure will be mapped out in SAP ERP. In addition, you will see how this organizational structure will affect your master data structures and maintenance process. Lastly, you will be introduced to the concept of configuration in the SAP ERP Implementation Guide (IMG).

Unit Objectives

After completing this unit, you will be able to: • Describe the purpose of a plant in SAP ERP

• Describe the purpose of a storage location in SAP ERP • Describe the purpose of an MRP area in SAP ERP

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Lesson:

28

Plants

Lesson Overview

In this lesson you will learn about plants in relation to the organizational structure and how they are integrated into master data.

Lesson Objectives

After completing this lesson, you will be able to: • Describe the purpose of a plant in SAP ERP

In the past this course has never expanded on organizational structures. The point of this unit is to show participants how important the plant is, especially the plant calendar since it will affect both order scheduling and Planned independent requirements (forecast)

Business Example

Your company currently has many locations where they store and manufacture products. In order to make the most of out of your implementation, you must be aware of how to model various installations in SAP ERP. You want to learn more about how the SAP ERP plant will fit your supply chain model.

Plants in SAP ERP

The plant is a logistics-based organizational element that is used by all the logistics modules. The plant is assigned to a company code, and a company code may have many plants assigned to it. In production planning, the main organizational element is the plant. A plant is typically configured in conjunction with the company code and valuation area due to tax rules and regulations

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TSCM40_I Lesson: Plants

Figure 13: Definition of a Plant

A plant may be defined for different purposes, depending on the role the plant will have in the organization. In Sales and Distribution, a plant can represent the location from which finished goods materials are stored and distributed. A plant may also be the location from which services are rendered. In materials management, a plant represents a location where material flow is managed. Stock requirements are managed from inbound and outbound perspectives. Material stock is consumed, planned and purchased in the plant. In production, a plant represents a manufacturing facility where materials are produced.

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When creating a new plant, you can use the plant copy function. In the process, all entries in the plant table and all Customizing and system tables that depend on it (and in which the plant occurs as the key) are taken into account. A plant is defined in the system by means of a four-character alphanumeric key that is unique in the client.

Once a plant is configured, it must be assigned to several other organizational elements to assure cross-functional integrations. Here is an example of where the plant will be assigned:

• Company code • Business area • Sales organization • Purchasing organization

Plants are often determined as single geographical locations where those

necessary business functions must be tracked. In certain situations, companies can combine several locations that are closely geographically located into one plant to minimize the organizational hierarchy. Due to tax reasons, some companies will split a single location into multiple plants. For example, companies will sell their finished goods to another company immediately after production, while the distribution location belongs to another facility. Both plants may exist in the same geographical location, but remain as two separate plants reporting to two separate company codes.

As mentioned earlier, the plant is the key focal point for production planning. All master data, planning, and execution activities are defined and performed the plant level. Some examples of these dependencies are:

• Calendar • Material master • Bill of material • Work center • Routing

• Planned/production order types • MRP configuration

Demonstration: Configuration of a Plant

Purpose

Create a Plant

System Data

System: Client:

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User ID: Password:

1. Demonstrate the configuration of a plant. Follow IMG Menu Path:

Enterprise Structure → Definition → Logistics-General → Define, copy, delete, check plant

2. Select Define Plant. Select Plant 1000 and select Details

Note: Point out the Factory Calendar that is assigned to the plant. Inform participants that this calendar will affect order scheduling and demand during planning.

3. Select Back twice to the pop-up window and select Copy, delete, check plant. 4. Select Copy Org. Object

5. Enter Copy From 1000 and copy to P114 and select Continue (Enter)

6. Once completed exit to the main menu and demonstrate the following IMG transactions

7. IMG Menu Path: Enterprise Structure → Assignment → Logistics-General

→ Assign plant to company code

Review Company code 1000

-Note: Plant P114 has been assigned to company code 1000. 8. IMG Menu Path: Production → Shop Floor Control → Master Data →

Order → Define Order-type Dependent Parameters

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31

Configuring a Plant

1. Choose Enterprise Structure → Definition → Logistics-General → Define,

copy, delete, check plant.

2. Choose Define Plant. Select Plant 1000 and choose Details.

3. Select Back twice to the dialog box and select Copy, delete, check plant. 4. Choose Copy Org. Object.

5. Enter 1000 in Copy From field and P114 in Copy To field and choose

Continue (Enter).

6. Once completed, exit to the main menu.

7. Choose Enterprise Structure → Assignment → Logistics-General → Assign

plant to company code.

Review Company code 1000.

Note: Plant P114 has been assigned to company code 1000.

8. Choose Enterprise Structure → Assignment → Logistics-General → Assign

plant to company code.

Review Company code 1000.

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Facilitated Discussion

Lesson Review

Discussion Questions

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Lesson Summary

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TSCM40_I Lesson: Storage Locations

Lesson:

33

Storage Locations

Lesson Overview

In this lesson you will learn how the storage location is incorporated into the organizational structure and how it impacts master data in production planning.

Lesson Objectives

• Describe the purpose of a storage location in SAP ERP

In previous versions of this class storage locations were never given much consideration. The group responsible for inventory management will typically control these. However, manufacturing will decide if backflushing is done or MRP Areas will be needed. This requires participants to have a more thorough understanding of storage locations in SAP ERP.

Business Example

Your company currently has many areas where they store products within a facility. In order to make the most of out of your implementation, you must be aware of how to model areas in SAP ERP. You want to know how the SAP ERP storage location will fit your supply chain model for planning and execution purposes.

Storage Locations in SAP ERP

The storage location is an organizational unit that facilitates the differentiation of stocks of materials within a plant. Inventory management on a quantity basis is carried out in the plant at storage-location level. The physical inventory is also carried out at this level within materials management and Inventory Management.

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Figure 15: Storage Locations in SAP ERP

As with all organizational elements, storage locations are configuration and are defined in the IMG. A storage location is defined by means of a four-character alphanumeric key that is unique in the plant.

The enterprise structure is created through the assignment of organizational levels to each other. A client may therefore contain several company codes. In turn, a company code may contain several plants. However, a plant can only ever belong to one single company code in the SAP system.

Hint: Since the plant key is unique in a client, and a plant can only belong to one company code, by specifying the plant you simultaneously specify the company code.

Several storage locations may be assigned to a plant, but when a certain storage location is assigned to a plant it forms a compound key. Storage locations are defined especially for a plant and are thus assigned to this plant. The storage location key need only be unique within a plant. Within a client, the same key can be used for different storage locations, since when you specify a storage location you always have to specify the plant as well.

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Figure 16: Storage Location Address

Note: To create storage locations, in the IMG, choose Enterprise Structure

→ Definition → Materials Management → Maintain Storage Location.

Here you can create a storage location in reference to a plant.

Upon creating a storage location, you will define a unique four-character value. This value is alphanumeric, so a company could create an exhaustive number of storage locations for each facility. In addition, when creating a storage location, companies have the opportunity to define a different address for each storage location. This may be done for one of several reasons:

• The storage location represents a sub-contractor location where inventory is held.

• The storage location represents a company facility with a different shipping address.

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The material master record is automatically extended the first time a goods receipt is posted for the material. All data specific to the storage location is updated in the material master record. The system can be configured in this way in Customizing by choosing Materials Management → Inventory Management and Physical

Inventory → Goods Receipt → Create Storage Location Automatically.

In this step, you specify whether the automatic creation of storage location data is allowed for goods receipts. This is advisable if you want to post a goods receipt without having to maintain the storage location view of the material master record in advance. First, you have to allow automatic creation per plant. You then have to explicitly allow the creation of storage location data for each movement type. The storage location data is only created if the quantity is posted to “standard” storage location stock. It is not created for receipts into a special stock (for example, into sales order stock).

Note: The standard system is set in such a way that the storage location data is created automatically for all types of receipts (goods receipt with or without reference, stock transfers, initial entry of stock balances, reversal of goods issues, and so on).

To manually create storage locations, enter the storage locations for a material master record collectively. This is much less time-consuming than entering the data for each storage location individually. This can be performed from the application menu path by choosing Logistics → Production → Master Data →

Material Master → Other → Enter Storage Locations (MMSC).

Once a material exists in a storage location users, will see a Storage location view on the material master. In addition, they will be able to make settings for material requirements planning (MRP) at the storage-location level in the MRP 4 view.

Demonstration: Configuration of a Storage Location

Purpose

Demonstrate to Participants how to create a new Storage location for your plant P114 System Data System: Client: User ID: Password: Set up instructions:

1. To create storage locations follow the IMG menu path: Enterprise Structure

→ Definition → Materials Management → Maintain Storage Location.

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3. Enter Plant P114 4. Choose New Entries

5. Enter the storage location number OS01, and a description of Off Site 1 6. Select the new storage location and select the folder Addresses of Storage

locations TWICE

7. Choose new entries, and place a 1 in theNO. (sequential Address number) Field, and put any address in the fields

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37

Configuring a Storage Location

1. In the IMG, choose Enterprise Structure → Definition → Materials

Management → Maintain Storage Location.

2. Choose Execute.

3. Enter Plant P114 and choose Continue.

4. Choose New Entries.

5. Enter the storage location number OS01 and a description of OFF Site 1. 6. Select the new storage location and select the folder Addresses of Storage

locations twice.

7. Choose new entries, place a 1 in theNO (sequential address number) field, and put any address in the fields.

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Facilitated Discussion

Discussion Questions

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Lesson Summary

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TSCM40_I Lesson: MRP Areas

Lesson:

39

MRP Areas

Lesson Overview

In this lesson we will discuss the concept of MRP areas and how they may be an alternative to creating additional plants in your organizational model.

Lesson Objectives

After completing this lesson, you will be able to: • Describe the purpose of an MRP area in SAP ERP

This lesson is to be position to the participants as a possible alternative to modeling multiple plants within a given location. For example a ship yard may be laid out over several square kilometers/miles, with various buildings. Instead of each building being a plant, MRP areas May be an alternative to creating multiple plants.

Note: MRP Areas are only related to planning, so they have no financial impacts

If more information is required, direct students to the online help or SCM240.

Business Example

Your company currently has many areas where they store products within a facility. To make the most of out of your implementation, you must be aware of how to model areas in SAP ERP. Often times your company has requirements to keep inventory and demand separate from other areas of the business. You want to know how the SAP ERP MRP area will fit your supply chain model for planning and execution purposes.

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Note that MRP areas are not part of the standard org structure. However they will use storage locations as part of their definition. This may lead to creating addition storage locations to use with MRP Areas, than what was previously decided.

Figure 17: Organizational Structure Overview

In many situations, the logistics side of the business has specific requirements from customers to keep inventory and demand separate from other streams of demand. This may be due to subcontracting requirements or storing spare/service parts separate from the rest of the facility. One option companies have is creating a separate plant, but from a configuration standpoint this requires a lot of overhead and possible maintenance while having no positive financial impact.

MRP areas are not part of the physical organization structure, but can use the storage locations within a plant to break up requirements and inventory during planning.

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Figure 18: MRP Areas

MRP areas are defined as part of MRP configuration. There are three types of MRP areas: plant, storage location, and Vendor (subcontractor). We will only focus on the storage location aspect since that can affect the modeling of your organizational structure.

Note: To find MRP Areas in the IMG, choose Production → Materials

Requirements Planning → Master Data → MRP Areas → Define MRP Areas.

When creating MRP areas, you must specify the MRP area type, plant, and receiving storage location for Type 2 (storage location). Companies have the options of assigning one or more storage locations to each MRP area. Once an MRP area is defined, users must assign material masters to the MRP areas they wish to segregate from the rest of the plant.

Note: When demand is placed at the storage location level – either through sales order, demand management, or via some dependent demand – if the material master is assigned to an MRP area that contains the storage

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System Data System: Client: User ID: Password: Set up instructions:

1. IMG Menu path to MRP Areas: Production → Materials Requirements

Planning → Master Data → MRP Areas → Define MRP Areas

2. Select New Entries

Field Value

MRP Area OS01-P114

Description Out Sided Storage

MRP Area Type 02 - Storage Location

Plant P114

3. Press Enter

4. Enter receiving storage location OS01, and select Save

5. From the application menu follow: Logistics → Production → Master Data

→ Material Master → Material → Change → immediately

6. Enter T-F1## and select MRP 1 at Plant 1000.

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42

Using MRP Areas

1. In the IMG, choose Production → Materials Requirements Planning →

Master Data → MRP Areas → Define MRP Areas.

2. Choose New Entries and enter the data from the table below.

Field Value

MRP Area OS01-P114

Description Out Sided Storage

MRP Area Type 02 - Storage Location

Plant P114

3. Press ENTER.

4. Enter receiving storage location OS01and choose Save.

5. From the application menu, choose Logistics → Production → Master Data

→ Material Master → Material → Change → immediately.

6. Enter T-F1## and select MRP 1 at Plant 1000. 7. At the bottom of the MRP 1 screen, select MRP Areas.

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Facilitated Discussion

Review why a company might use MRP areas instead of plants.

Discussion Questions

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Lesson Summary

• Describe the purpose of an MRP area in SAP ERP

Related Information

For more information as it pertains to production planning, see online help or SAP course SCM240.

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Unit Summary

• Describe the purpose of a plant in SAP ERP

• Describe the purpose of a storage location in SAP ERP • Describe the purpose of an MRP area in SAP ERP

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Unit 4

45

Material Masters

In this unit you will demonstrate to the participants the different phases of a material masters life cycle. This will include, creation, updates, and deletion. In this unit you will create several material masters that will be used in the bill of material lessons.

Unit Overview

In this unit you will be introduced to the concept of the SAP ERP material master. You will be instructed on the creation, maintenance, and configuration of the material master. In addition, you will execute various transactions to manage the process surrounding its life cycle.

Unit Objectives

After completing this unit, you will be able to:

• Describe the organizational layout of the material master • List the prerequisites to creating material masters • Use various methods to create material masters

• Describe the request process with interactive forms and explain how it might benefit your business

• Describe how the material master can use classification to include company-specific fields

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Unit Contents

Lesson: Overview of the Material Master... 63 Demonstration: Organizational Levels of the Material Master... 66 Procedure: Organizational Levels of the Material Master... 67 Lesson: Creating a Material Master ... 70 Demonstration: Prerequisite for Creating Material Master ... 77 Demonstration: Setting Up Defaults ... 80 Demonstration: Creating a Material from Scratch... 81 Demonstration: Setting Up MRP Profiles ... 82 Exercise 1: Creating Material Masters... 87 Lesson: Classification of the Material Master ...102 Demonstration: Updating the Material Master ...103 Demonstration: Demonstrate Set up of Classification ...106 Demonstration: ...108 Demonstration: Demonstrate Batch classification of the material Master... 110 Demonstration: Demonstrate variant configuration of the material master... 113 Exercise 2: Material Classification ... 115 Lesson: Managing the Material Master ...122 Demonstration: Extending the Material Master...124 Demonstration: Changing the Material Type...125 Demonstration: Change Material Master MM02 ...126 Demonstration: ...128 Demonstration: Demonstrate Updating Material Masters with Mass Maintenance...130 Demonstration: Demonstrate Archiving the Material Master ...134 Exercise 3: Managing Material Masters ...139

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TSCM40_I Lesson: Overview of the Material Master

Lesson:

47

Overview of the Material Master

Lesson Overview

In this lesson you will learn about the material master at a high level and its purpose in SAP ERP.

Lesson Objectives

• Describe the organizational layout of the material master

This lesson is designed to be an overview for the material master to gain introduce them to a specific topic. The important element of this lesson is to ensure students know the data exists in multiple tables and are attached to organizational structures.

Business Example

As the project lead for implementing material master files, you must be aware of the structural design of the objects in SAP ERP. You want to learn how the material master is structured to integrate it with several business areas in your company.

Introduction to the Material Master

The material master contains information on the materials that a company constructs, procures, manufactures, stores, and sells. The information is stored in a database that is a central source of data on materials. The material master record integrates data from different areas of a company.

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Figure 19: The Material Master

For a company, the material master record represents the central source for data on materials, and is used by various SAP logistics applications. The material can be a finished product (product or article), a semi-finished product (subassembly), or a raw material (purchased part).

The material master can be valid for many different areas within the business. All data is maintained in several centralized tables, based on relevance to the particular part of the organizational structure. The material master is used by all SAP R/3 logistics applications. It controls whether a material is purchased, produced, or sold.

Every area of responsibility can have a material master view. Because different user departments in a company work with the same material, and each of these departments wants to store different information on the material, you can subdivide material master data according to the department to which it belongs. Each department then has its own material master record view and is responsible for the data being correct.

The data that you maintain in the following views is used by production planning (PP) functions:

• The basic data view includes general data, such as the material number, material description, base unit of measure, and technical data.

• The classification view contains user-defined class assignments for a material.

• The materials planning view contains plant-specific data used in procurement planning.

• The scheduling view contains plant-specific data used for scheduling materials for production.

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TSCM40_I Lesson: Overview of the Material Master

Figure 20: Organizational Levels of the Material Master

Some material data is valid on all organizational levels and other data is only valid for specific levels. So that the material data can be managed centrally in the company without clogging up your data with redundant information, the material master is structured hierarchically, reflecting a company’s structure. In SAP ERP, the only elements that directly impact production planning are client, plant, and storage location.

 General material data that applies to the whole company is stored on client level. This includes material descriptions, base units of measure, and conversion factors for alternative units of measure. This data is contained in the table MARA.  All data that applies to a plant and its assigned storage locations is stored on plant level. Examples of this kind of data are MRP and forecasting data. This data is contained in the table MARC.

 All data that applies to a specific storage location is stored on storage location level. This is mainly storage location stock. This data is contained in the table MARD.