SAP Production Orders

LO215 Production Orders

LO215

0

SAP AG 1999

LO215

Production Orders

 SAP AG

LO215

LO215

Production Orders

Production Orders

 System R/3  Release 4.6C  October 2000  5004 2355

0.2

SAP AG 2004

Copyright 2004 SAP AG. All rights reserved.

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SAP AG. The information contained herein may be changed

without prior notice.

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0.3

SAP AG 1999

Production Planning

Level 2

Level 3

Manufacturing Planning & Execution for Discrete & Repetitive

LO050 5 days Engineering Change Management LO980 3 days Batch Management LO955 3 days KANBAN LO235 2 days Classification LO985 3 days Special Features of LIS in Production LO275 2 days Logistics Info Planning LO935 2 days CAP Calculation of Standard Values LO720 2 days Repetitive Manufacturing LO225 3 days Capacity Planning LO230 5 days Logistics Information System (LIS) Reporting LO930 2 days Basic Data Part 2 LO206 3 days Basic Data for

Discrete Manufacturing LO205 3 days Production Orders LO215 5 days Production Planning LO210 5 days Variant Configuration Part 1 LO990 5 days Variant Configuration Part 2 LO991 3 days

0.4

SAP AG 1999

Requirements

Necessary:

Knowledge of Production Planning and

Control

LO205 Basic Data for Discrete

Manufacturing

LO206 Basic Data Part 2

Recommended:

LO050 Manufacturing Planning and

0.5

SAP AG 1999

Target Group



Members of the project team who are responsible

for the implementation of production orders

(consultants and administrators)



Managers and employees in production areas

(production schedulers, controllers, supervisors

and operators)



Duration: 5 days

Information for participants

 The training materials are not designed to be a self-teach program. They are only complete when used in

conjunction with the explanations of the instructor. You are given space on each page of the training materials to write down this additional information.

1

SAP AG 1999



Course Goals



Course Objectives



Course Content



Course Overview Diagram



Main Business Scenario

1.2

SAP AG 1999

At the conclusion of this course, you will be

able to:

Course Goal

SAP AG 1999



Use production orders.



Create, release and fully implement

production orders. You will be able to

make system settings and also understand

production orders in context.

1.3

SAP AG 1999

 Classify production orders in the production planning and

execution environment (demand management, requirements and materials planning, sales order processing and so on)

 Implement or apply production orders and their most

important functions

 Understand and use the basic order management functions

in detail

 Use the information systems for production orders

 Take into consideration the integration relationships within

the production order

 Teach yourself additional special functions

Course Objective(s)

At the conclusion of this course, you will be able to:

1.4

SAP AG 1999

Unit 8 Order Control Unit 9 Confirmations Unit 10 Goods Receipt

Unit 11 Settlement, Archiving and Deletion

Unit 12 Information Systems Unit 13 Mass Processing and

Automation Unit 14 Collective Orders Unit 1 Introduction

Unit 2 Overview

Unit 3 Order Structure / Processing Unit 4 Order Creation /

Order Change Unit 5 Order Release

Unit 6 Printing Order Documents Unit 7 Material Staging

Preface

Appendix

Course Content

1.5

SAP AG 1999

Course Overview Diagram (1)

Goods Receipt Goods Receipt

10

10

Confirmations Confirmations

9

9

Information Systems Information Systems

₁₂

₁₂

Settlement

Settlement,,ArchivingArchiving

and

andDeletionDeletion

11

11

Collective

CollectiveOrdersOrders

14

14

Mass Processing

Mass Processing

and Automation

and Automation

13

13

Material

MaterialStagingStaging

7

₇

1

1

1

Order

OrderStructureStructure//

Processing Processing

3

3

Order Control Order Control

₈

₈

Printing Printing Order

OrderDocumentsDocuments

6

6

Order Release

Order Release

₅

₅

Order

OrderCreationCreation //

Order Change

Order Change

4

4

Overview

Overview

₂

₂

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SAP AG 1999

Course Overview: Main Business Scenario

Your company manufactures order-related products.

You belong to the team in your organization that implements the part of production planning and control dealing with R/3 production orders. This means implementing the whole

process chain for in-house production, which will allow your company to organize, steer and execute plant production using the R/3 System.

Important stages of order-related manufacturing are creation, release, machine usage, printing of papers, material

withdrawal, execution, confirmation, goods receipt and settlement.

In practice, these functions are integrated into other areasin your company (controlling, material management and so on). It is therefore necessary to consider the extensive integration relationships during implementation.

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SAP AG 1999

Overview: Contents



Overview of the process chain for order-related production



The process chain in other production planning and

control scenarios



Characteristics of order-related production



Order-related production in the organization structures of

the R/3 System

2.2

SAP AG 1999

At the conclusion of this unit you will be able

to:

Overview: Topic Objectives

SAP AG 1999

 Recognize the different steps in the process chain for order-related production

 Recognize the most important characteristics of order-related production

 Define how production orders are classified in the R/3 application component PP and in the organization structures

2.3

SAP AG 1999 Goods Receipt Goods Receipt

10

10

Confirmations Confirmations

9

9

Information Systems Information Systems

₁₂

₁₂

Settlement

Settlement,,ArchivingArchiving

and

andDeletionDeletion

11

11

Collective

CollectiveOrdersOrders

14

14

Mass Processing

Mass Processing

and Automation

and Automation

13

13

Material

MaterialStagingStaging

7

₇

Order Control

Order Control

₈

₈

Printing

Printing

Order

OrderDocumentsDocuments

6

6

Order Release

Order Release

₅

₅

Order

OrderCreationCreation //

Order Change Order Change

4

4

Overview Diagram (2)

Introduction Introduction

₁

₁

2

2

Order

OrderStructureStructure//

Processing

Processing

3

3

Overview

2.4

SAP AG 1999

Production Orders in Practice

Production by lot size

Production by lot size

Make-to-order production Make-to-order production "Special" engineer-to-order production "Special" engineer-to-order production P R O D U C T C O M P L E X I T Y P R O D U C T S T A B I L I T Y Assembly production/ Assemb.-to-order prod. Period-oriented production/ flow manufacturing with takts Mass production Process manufacturing

 You can apply the R/3 Production Planning System in a variety of production types.

 The production types used in practice are essentially dependent on product stability, product

2.5

SAP AG 1999

Subsystems of the PP Application

PP

PP

PP PC Prod. Costing PP IS Prod. Info System PP MRP Mat. Rqmts Planning PP SOP

Sales & Oper. Planning PP MPS Demand Mgmt PP BD Basic Data PP PP SFC SFC Shop ShopFloorFloor

Control Control PP PI Process Mfg PP REM Rep. Mfg PP CRP Capacity Planning PP KAN KANBAN

 The Production Planning (PP) application incorporates a number of integrated working subsystems.  Each time you use the R/3 system, you should determine precisely which components are appropriate

to your needs.

2.6

SAP AG 1999

Order-Related Production: Characteristics (1)



Order-related production



Based on production orders with order category '10'



Production by order lot sizes (see Lot-Sizing Procedure)



Integrated logistical and controlling functionality



Production by production versions (for example,

production lines)



Detailed status management



Full integration into capacity planning



PDC - Interface (PP-PDC) for download and upload

2.7

SAP AG 1999

Order-Related Production: Characteristics (2)



Availability checks for material, capacity, production resources

and tools



Various options for entering actual data (quantity, time)

 Order, operation, time event and progress confirmations



Extensive order-related or product-related controlling



Full integration in the Logistics Information System (LIS) and

Business Information Warehouse (BW)



Archiving and retrieval function



Numerous special functions

 multi-level collective orders, trigger points, serial numbers, order

split, external processing, rework, WIP, variance calculation, cross-plant production, batch creation and batch determination, co-products and so on

2.8

SAP AG 1999

Cross-Application Functions

Material forecast Sales & Distribution

Inventory E A C D B

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in

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C

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ac

it

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p

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in

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C

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in

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C

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st

in

g

Demand program Sales reqmts Planning

Requirements planning

Production order

Production order

Order

Orderprocessingprocessing

Goods receipt

Goods receipt

Order

Ordersettlementsettlement

Goods issue Goods issue Purchase requisition Purchase order Goods receipt Invoice receipt Planned order Planned order

 Production order management is a central component of a complex process chain that starts with

independent requirements (planned or customer requirements) and ends in the issue of a finished

product.

 Production order management in the SAP System only controls the whole process of in-house

production.

 Production order management uses the following system components:

ALE, Workflow, Customizing, word processing, factory calendar, classification, communication and graphics.

2.9

SAP AG 1999

Production Planning and Control Data

Confirmations

CO object (cost collector)

Material movements (goods receipt / issue) Production orders Factory calendar Mat. master Work centers Bills of material Routings Prod. resources/tools CAPP formulas Documents Master

Masterdatadata

Transaction

Transactiondatadata

 Data that does not change frequently is defined as master data of the Production Planning System.  Transaction data are documents that have a restricted time application. In the Production Planning

System these are production orders.

 Documents for confirmations, costs (CO objects) and material movements are assigned to the production

2.10

SAP AG 1999

Corporate Order Management

Order

Assignment to a material

Order

Order

Order

Overhead cost orders Capital investment orders

Goods for the market Internal company goods and services Sales-Related Goods sold Goods in stock Company Internal Cannot be

activated Can be activated

Customer Warehouse Cost center Asset portfolio Logistic functions (quantities and values) Cost accounting functions (values)

Assignment to a sales order

 Corporate order management is divided into two basic forms: Sales-related orders and company

internal orders.

 Within company internal orders, a distinction has to be made between:

Orders purely for object control within cost accounting (for example, for promotional purposes or for use in trade fairs). Productive and value-added orders that can be activated (for example, for in-house production on a production line).

 In the R/3 System, both basic order forms are assigned to SAP applications via order category.  Examples: Production order (PPS) -> PP Production Planning

Plant maintenance order-> PM Plant Maintenance

Network -> PS Project System

Overhead cost order -> CO Controlling

2.11

SAP AG 2003

Document Type, Order Category, Order Type

Material accounting documents Financial accounting documents Orders PP process order PS network CO internal order CO production order CO model order

PM plant maintenance order

Production order (external number range) Production order (special types)

Production order (internal number range) PP production order Document type Document type Order category Order category Order type Order type

 The document type is used to differentiate between business transactions in the R/3 System.  Orders are one category of business transaction.

 Orders are divided up according to order category, as it is possible to have different orders within the

different applications.

 The system predefines fixed order categories for each application.

 You have the option of individually defining order categories for each order type within an application.  An order type is used to control different processes:

Number assignment Setting default values

User-specified status management

User-specific field control (not for production orders in Release 4.7) Control of special functions (activating BDE, QM, LIS,....)

2.12

SAP AG 1999

Definitions in the Production Order

What

Whatisisbeing producedbeing produced?? When

Whenisisit beingit being

produced

produced??

How much has

How much hastotobebe

produced

produced??

For whom are we producing

For whom are we producing?? (

(costcostobject)object)

Which resources

Which resourcesandandmethodsmethods

are being used

are being usedin the in the productionproduction?? Which costs are incurred by

Which costs are incurred bythethe production

production??

Products Activity

Planned order dates Basic order dates Calculated dates Confirmed dates Release

Start Final

Planned order quantity Production order quantity Confirmed quantity Material Cost center Order Asset Material usage Prod. resources/tools Checks Planned Actual

2.13

SAP AG 1999

Production Orders and Organizational Structures

Organizational units

Organizational units

Production order Shop floor control Demand management Requirements planning Inventory management Company Controlling areas Sales organizations Company codes Valuation areas Plants Plants

Storage locations/batches/special stocks

Purchasing organizations

 Production orders generally relate to the organizational unit plant.  The organizational units above a plant can be structured in various ways.

2.14

 SAP AG 1999

Master Data for the Production Order

 Required quantity and usage value  Control data

 Required quantity and usage value  Control data BOM Routing Material Material BOM BOM Work center Work center Routing Routing Prod

Prod. . resourcesresources//toolstools

 Material usage (Mat. no., item cat., quantity)  Storage location (proposal for withdrawal)

 Operation default values

 Available capacity and formula requirements  Activity type and formula costs

 Operations  Standard values

 Procurement type E or X

 MRP, work schedule, acct. and costing data  Material status (MARA and MARC)

 The material to be produced must have already been designated procurement type in house

production (X,E).

 The material status must be released for production on both a cross-plant level (MARA) and a plant

level (MARC).

 At least one plant specific view (MRP and/or work scheduling) as well as financial accounting and

costing views must be maintained for the material.

 You prepare BOMs as single level BOMs. A special selection procedure chooses the correct BOM.  After you have prepared a routing, a special selection procedure chooses the correct one.

2.15

SAP AG 1999 Production Production Production operator Production scheduler (supervisor) Production preparation Production

preparation analysisDocu. & Docu. & analysis Industrial engineer Sales planning Sales planning Design engineer Plant reqmts Detailed Planning Production planner Plant manager MRP controller Production scheduler Production operator Production scheduler Plant manager Quality inspector

Order-Related Production - Roles

 Within the development of the SAP product "mySAP.com", computer-supported work centers have

been created along the entire process chain for order-related production.

 Production order management touches on at least those roles shown on the slide.

 Individual roles are assigned different activities (tasks), authorizations and responsibilities that

2.16

SAP AG 2003

Production Order - Symbol Overview

Order header

Detail screen (operation, component, PRT, ...)

Sequence overview Component overview Operation overview Document overview Status overview Key

Collective order overview

Log

Trigger point overview

Change Display

Save

Deletion

Schedule (order, collective order)

Cost

Check availability (material, capacity, PRT)

Release (order, operation)

Print

Enter long text (text editor)

Generate object (for example, order)

Execute program (function)

Update

 The slide shows the most frequently used pushbuttons (symbols) in the production order.

 The symbols have been arranged on the individual production order screens in such a way that you can

always find the relevant symbol in the same place on the screen.

 Order functions are arranged on the left and navigation functions on the right.

 In the overviews of the operations, components and production resources/tools, the relevant pushbuttons

for the individual object have been arranged underneath the overview.

2.17

SAP AG 1999

• Order type

LO215 - Commonly Used Abbreviations

Table T399X

SPRO + SFC + Master Data + Order-Type Dependent Parameters

• Order type parameters

Table T003O

SPRO + SFC + Master Data + Order Types

• PP-SFC

• Scheduling parameters of the order type

Table TCX00_FA

SPRO + SFC + Operations + Scheduling + Scheduling Parameters

Production Planning - Shop Floor Control

SAP + LO + PP + Shop Floor Control

• Customizing Transaction SPRO

SAP + Tools + Accelerated SAP + Customizing + Edit Project

• Task menu (SAP) Transaction session_manager

 During the LO215 course, the instructor may repeatedly use certain terms, tables and shortcuts. The

slide contains the most important terms and their menu paths.

2.18

SAP AG 1999

You have gained an overview of the process chain for order-related production and the role it plays in the R/3 System.

You have learned about the prerequisites for master data. You have been informed about the role of order

management in the organization structures of the R/3 System.

The orders are assigned to an application using the order category. This determines the scope of the functions. The order types serve as a control for special functions

per order category.

3

SAP AG 1999



Order data structure



Production order screens



Overview of order processing

3.2

SAP AG 1999

Order Structure and Processing: Course

Objectives

At the conclusion of this unit you will be able

to:

 Describe production order data structure  Describe the most important production order

screens

3.3

SAP AG 1999 Goods Receipt Goods Receipt

10

10

Confirmations Confirmations

9

9

Information Systems Information Systems

₁₂

₁₂

Settlement

Settlement,,ArchivingArchiving

and

andDeletionDeletion

11

11

Collective

CollectiveOrdersOrders

14

14

Mass Processing

Mass Processing

and Automation

and Automation

13

13

Material

MaterialStagingStaging

7

₇

3

3

Order Control Order Control

₈

₈

Printing Printing Order

OrderDocumentsDocuments

6

6

Order Release

Order Release

₅

₅

Order

OrderCreationCreation //

Order Change Order Change

4

4

Overview Diagram (3)

Introduction Introduction

₁

₁

Overview Overview

₂

2

Order

OrderStructureStructure// Processing Processing

3.4

SAP AG 1999

Elements of an Order

Order header Order header Operations Operations Capacity splits Capacity splits Material

Materialcomponentscomponents

Prod

Prod..resourcesresources//toolstools

Trigger Points Trigger Points Confirmations Confirmations Order number Plant Production scheduler Work center Control key Standard values Individual machine Individual person Settlement rule Settlement rule Settlement profile Settlement receiver Material number Quantity Reqmts date PRT number PRT category Number Functions Quantities Times Costs Costs Planned Actual Document links Document links Doc. number Doc. category Operation

Operationsequencessequences

Standard sequence Other sequences

 The order structure can be enhanced by adding certain elements.

 At least one operation is required. The system automatically creates this operation when missing.  You have the choice of whether or not to assign material components, production resources / tools

and trigger points to the operation.

 You can create several (parallel) operation sequences.

 You can make a selection from several alternative sequences.  Suboperations are permitted within an operation.

 Costs are determined at operation level and submitted at order header level only in the case of

3.5

SAP AG 1999

Production Order - Header

1000767

General Assignment Goods receipt Control Dates/quantities Master data

Order type Order number Plant Material or activity Quantities dates To Routing To BOM To Costing Entered by / Changed by Plants Assignments MRP controller

Control of goods receipt Movement type Settlement rule Settlement receiver Percentages Deadline monitoring Quantity monitoring Product (activity) to be manufactured with the order

Manual Planned order

Definition Origin

Order Functions Edit Goto Header Environment

 The segment of the order header describes the product that is to be manufactured with the production

order (finished product, assembly, individual part).

 There are a series of detail screens for the order header.

 The header text of a production order can either be the short text of the material master or the header

text of the routing that has been copied into the production order (with reference to this, see the switch in table T399X).

3.6

SAP AG 1999

Production Order - Operation

1000767

Stand. values Ext. processing Interoperation times Standard value calc.

Operation 0010 Operation overview Single step in Order Manual Routing Operation Suboperation

Definition Origin Types _{General Data}

Standard values Ext. processing Interoperation times Standard values calc. Splitting Overlapping Operation dates User fields Quantities/activities Confirmed dates Order Functions Edit Goto Operation Environment

General Data

 This segment of the operation describes the individual work steps of the production order.  There are a series of detail screens for an operation.

 These screens, in turn, incorporate further detail screens.

For example, you can branch from the component overview to screens for each material component.

 You have the option of inserting suboperations hierarchically with reference to an operation.

 This enhances calculation and capacity planning.

The operation control key of the sub-operation plays an important role in this.  Scheduling always occurs at operation level.

 The standard values of the suboperations can be cumulated on the corresponding operation when the dimension and units of measurement are the same.

3.7

SAP AG 1999

Production Order - Material Components

1000767

Purch.data VarSzeltmDta Co-product Text item

Compon. 0010 Material number Material description Requirements qty Reqmts date Reservation Item category Bulk mat. indicator Available quantity Issued quantity

Missing parts quantity Text editor

Origin Definition

Materials required for an operation or for manufacturing a product

Manual BOM

Planned order

Order Functions Edit Goto Component Environment

General data

 In a production order, you can assign any number of material components to an operation.

 The segment for the material component describes the material required to carry out the individual

operations.

3.8

SAP AG 1999

Production Order - Production Resources/Tools

Definition

1000767

General Quantities Dates

Item 0010 Types Origin PRT number PRT control key Plant Requirements qty Usage value Formulas Usage dates Document (graphics) PRT text

Production resources/tools required

to execute an operation Manual Routing Material Equipment (as of 3.0) Document Other Order Functions Edit Goto PRTs Environment

 In a production order, you can assign any number of production resources/tools to an operation.

 The segment for production resources/tools describes the required devices, tools, test equipment and so

on required for executing an individual operation.

 The production resources/tools category is essentially derived from the demands on a production

3.9

SAP AG 2003

Production Order - Documents

P-100

Order Functions Processing Go to Document Environment

Doc. Data Additional Data Descriptions Object Links Original Document Document no. Subdocument Document version Assignmt to operation Origin Format Object link

Original appl. file(s) Storage data Definition

Production resources/tools required execute an order Origin Manual Material Master Bill of Material Prod.Version 000 00 Originals

 You can assign any number of documents to a production order. These are maintained in the

Document Management System (DMS).

 The documents themselves are only linked to the production order and not saved in it.  You can create links from documents to a production order manually or automatically.  Documents can be drawings, texts, videos and so on.

 Application example: Product descriptions

Assembly instructions and diagrams Inspection instructions and certificates Work instructions

Storage and transportation regulations Spare parts lists

3.10

SAP AG 1999 1000767

Costs arising during the

execution of a production order

Automatic Costing

Definition Origin

Order Functions Edit Goto Header Environment

Production Order - Costs

Overhead

Overheadcostscosts

Calculated in overhead structure

Production costs Production costs In-house production Activity price according to valuation variant Ext. processing

Price acc. to valuation variant

Material

Materialcostscosts Stock material

Price determination according to valuation variant

Non-stock material

Price from purch. info record

Process costs

Process costs

Assigned acc. to template Itemization Cost categories Cost comp. structure

 If order-related cost object controlling is used, each individual production order has a cost object

(CO).

 Order costs can be calculated manually or automatically.

You define this by setting up the order-type dependent parameters accordingly in Customizing (table T399X).

 The CO object enables you to display different lists of costs for a production order.  By choosing Goto + Costs in an order, you can find lists for the terms

Itemization (detailed overview of the individual costing items) Analysis (overview structured according to cost category)

3.11

SAP AG 1999

Production Order - Settlement Rules

Operations Operations Material components Material components Prod. resources/tools Prod. resources/tools Costs Planned Target Actual Costs Planned Target Actual 20 50 100 Order header Order header Definition Material Cost center CO order Asset WBS element

Sales order and so on

Manual Automatic

Receiver of order costs

Account assignment categories

Origin

 You control order settlement by way of settlement rules.  The order can be settled proportionally to one or more receivers.

 Settlement rules are created manually or automatically (during order creation).

At the latest, they must be maintained before the goods receipts posting is carried out for the material to be produced.

 You define the settings for order settlement in Customizing.

 If you use product-related cost object controlling, the settlement rules are contained in the product

3.12

SAP AG 1999

Processing a Production Order

1 1 Order request Order creation Availability checks Print order Material staging Order settlement Archiving / deleting Goods receipt Order release Confirmations 20 50 100 Determine WIP Calculate variances Order processing Machine reservation 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 Order header Order header Operations Material components Prod. resources/tools Costs Planned Target Actual

 The production order runs through a wide range of individual activities.

 WIP calculation, variance calculation and settlement are generally periodic operations for cost

object controlling that are processed in the background.

 You must define a series of settings for each individual stage if an order is to be processed successfully.  CO Configuration includes a special feature that sets the prerequisites for WIP determination, variance

3.13

SAP AG 1999

Order Structure and Processing: Summary

You have gained an overview of the data structure of a production order

You know the most important production order screens

The basic functions of production order management were shown in an example

3.14Exercise Data

Note:

There will not be sufficient time to work through

all the exercises during the course. The exercises

marked Optional should be seen as supplementary

examples that can be used, as required and time

permitting, during the course. Attendees can also

use these exercises after the course, to consolidate

what they have learned.

Explanation of the Symbols in the Exercises and Solutions

Exercises

Solutions

Course Objectives

Business scenario

Tips & Tricks

Data in the exercises

Type of data

Data in training system

(ID3, client 400)

Data in the IDES system

(ID3, client 800)

Group no.

xx (01....20)

User master records

LO215-xx password

FERT

Client

400 (401, 402) as per

training room

Customizing project

200

200

Company code

1000

1000

Business area

1000

1000

Purchasing

organization

1000

1000

Sales organization

1000

1000

Distribution channel

10 Final customer sale

10 Final customer sale

Division

00 Multiple division

00 Multiple division

Sector

M Mechanical

engineering

M Mechanical

engineering

Personnel area

1000

1000

Personnel subarea

Chart of accounts

INT

INT

Controlling area

1000

1000

Cost center hierarchy

H1

H1

Cost centers

4210, 4220, 4230

4210, 4220, 4230

Activity types

1410 Machine time

1420 Setup time

1430 Personnel time

1410 Machine time

1420 Setup time

1430 Personnel time

Factory calendar

01

01

Plants

1000 (Normal)

1100 (special structures)

1000 (Normal)

1100 (special structures)

MRP controllers

100, 101 Demo

001 to 002 Participants

099 Instructor

100, 101 Demo

Capacity planner

100, 101 Demo

001 to 002 Participants

099 Instructor

100, 101 Demo

Production scheduler

100, 101 Demo

001 to 002 Participants

099 Instructor

100, 101 Demo

Production scheduling

profile

0000001 Normal

0000002 automatic

0000001 Normal

0000002 automatic

Work centers

T-Exx

T-Fxx

T-Lxx

T-Mxx

T-Pxx

T-Vxx

T-WM

1111

1112

1116

1117

1310

1320

1721

1904

1905

1906

T-Exx

T-Fxx

T-Lxx

T-Mxx

T-Pxx

T-Vxx

T-WM

1111

1112

1116

1117

1310

1320

1721

1904

1905

1906

Material

(see also following

BOM structure for

T-F1xx)

T-F1xx Product

T-B1xx Assembly 1

T-B2xx Assembly 2

T-B3xx Assembly 3

T-B4xx Assembly 4

T-T1xx

Indiv.comp 1

T-T2xx

Indiv.comp

2

T-T3xx

Indiv.comp

3

T-T4xx

Indiv.comp

4

T-T5xx

Indiv.comp

5

P-100

100-100

100-200

100-300

100-400

100-110

100-120

100-120

100-310

100-210

Normal flow

Collective order

Config.var. scn. 1

Config.var. scn. 2

Config.var. scn. 3

Change

management

Normal flow

Rework

Automat.

Procedure

Limited no. of

Variants

W/o BOM and

plan

Select. BOM/plan

Op. consequences

Co-products

Mat. components

Mat. staging

Availability

Discontinued parts

Cross-plant

Split valuation

Batch production

Ext. Proc. / proc.

Serial numbers

Repetitive

/order-based production

Stock

determination

P-100

P-400

P-500

P-501

P-502

P-600

100-300

100-301

T-A

T-V1, V2

T-MAN

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

T-STOCK

P-100

P-400

P-500

P-501

P-502

P-600

100-300

100-301

T-A

T-V1, V2

T-MAN

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

T-STOCK

Bills of material

T-F1xx

P-100

P-400

P-500

P-501

P-502

P-600

T-A

T-V1, V2

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

P-100

P-400

P-500

P-501

P-502

P-600

T-A

T-V1, V2

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

Routings

T-F1xx

P-100

P-400

P-500

P-501

P-100

P-400

P-500

P-501

P-502

P-600

T-A

T-V1, V2

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

50000003 standard task

list

P-502

P-600

T-A

T-V1, V2

T-SEL

T-OS

T-COP

T-MC

T-MS

T-MA

T-MD

T-PDP

T-MV

T-BCH

T-EX

T-SN

T-REP

50000003 standard task

list

WM storage bin

PROD-1310

PROD-1310

Standard trigger

point

T-NACHARB

T-NACHARB

Order types

PP01 Demo and

exercise

PP03 Demo and

exercise

PP04 Demo and

exercise

PP01 Demo

PP03 Demo

PP04 Demo

PP06 Demo

PP07 Demo

PP06 Demo and

exercise

PP07 Demo and

exercise

PP08 Demo and

exercise

PP08 Demo

 SAP AG 1999

PP Exercise Material - BOM T-F1xx

T-F1xx (FERT, P-100) (1000, 0, _ ) 1 8 1 T-T1xx (ROH, 100-110) (1000, 1000, 2 ) T-T2xx (ROH, 100-120) (1000, 1000, 2 ) T-T3xx (ROH, 100-130) (1000, 1000, 2 ) 1 T-T4xx (ROH, 100-310) (1000, 1000, 2 ) 1 T-B1xx (HALB, 100-100) (1000, 10, 2 ) 1 T-B2xx (HALB, 100-200) (1000, 10, 2 ) (1100, 10, 2 ) 1 T-B3xx (HALB, 100-300) (1000, 0, _ ) 1 T-B4xx (HALB, 100-400) (1000, 10, 2 ) T-T0xx (ROH, 100-210) (1000, 1000, 2 ) 1 (1100, 1000, 2 )

Key: (Material, IDES template) (Plant, stock qty, sec. reqmts ind.))

Item 0010 0020 0030 0040 1 T-T5xx (ROH, 100-410) (1000, 1000, 2 ) Pos. 0010 0020 0030 0010 0010 0010 1 Dokument T-F1xx DRW, 000, 00 0050



SAP AG 1999 titel (author) 2

PP Exercise Materials - Routings

not assigned

10

TP-Lxx

( 1310 )

0010

T-Mxx

( 1310 )

0030

_T-Lxx

( 1906 )

0020

T-Vxx

( 1320 )

0040

_T-Exx

( 1904 )

0050

T-Fxx

( 1721 )

0060

_T-Pxx

( 1721 )

T-VH

hierarchy: T-V Assignment to stat. work center

and hierarchy

T-EH

hierarchy: T-E

T-F1xx

(FERT, P-100) (1000, 0, _ )

T-F2xx

(FERT, P-100) (1000, 0, _ )

3.15Order Structure and Order Processing Exercises

Unit: Order Structure and Order Processing

Topic: Order Structure and Order Processing

(LO215 Exercise 1)

•

Structure (data and contents) of a production order

In your capacity as production manager, production scheduler,

supervisor or operator, you work with production orders all the

time. In this exercise, you will become familiar with the structure

of a production order.

1-1

Display the production order no. _______________ .

Path:

S000

→

LO

→

PP

→

SFC

→

ORDER

→

DISPLAY

1-2

Display the individual data segments, screens and their data fields in the following

order:

Note any questions you may have about the meaning of the data fields.

If the meaning of any of the data fields is not clear, ask the instructor.

1-2-1 Order header screens

Select the corresponding tab index for the respective screen.

General

Assignment

Goods

receipt

Control

Dates/quantities

Master

data

Long

text

Settlement rule

Path:

→

HEADER

→

SETTLEMENT RULE

1-2-2 Overview of the operation sequences

Path:

→

GOTO

→

OVERVIEWS

→

SEQUENCES

1-2-3 Operation sequence details

Path:

→

SEQUENCE

→

DETAILS

1-2-4 Operation overview

Path:

→

GOTO

→

OVERVIEWS

→

OPERATIONS

1-2-5 Operation screens (select operation "0010")

Select the corresponding tab index for the respective screen.

General

Standard values

External processing

Interoperation times

Standard value calculation

Splitting

Overlap

Dates

User fields

Suboperation/dates

Quantities/activities

Confirmed dates

Qualification

Long text

1-2-6 Material components - Overview

Path:

GOTO

→

OVERVIEWS

→

COMPONENTS

1-2-7 Material component screens (select component "0010" or "0070")

Path:

COMPONENT

→

COMPONENT DETAILS

Select the corresponding tab index for the respective screen.

Item ’0010’

General Data

Item ’0070’

VarSzeltmDta

1-2-8 Overview of production resources/tools for operation "0050"

Path:

Go to the operation overview and select

operation "0050".

In the menu bar at the bottom of the screen, select the PRT pushbutton

(Production resources/tools)

1-2-9 Screens for the production resources/tools (select production resource/tool

"0020")

Path:

PRODUCTION RESOURCE/TOOL

→

PRODUCTION

RESOURCE/TOOL DETAILSHILFSMITTEL

Select the corresponding tab index for the respective screen.

Item ’0020’

General

Quantities

Dates

1-2-10 Document overview

Path:

GOTO

→

OVERVIEWS

→

DOCUMENTS

1-2-11 Display of the document information record (select the first document)

Path:

DOCUMENT

→

DISPLAY DOCUMENT INFORMATION RECORD

Select the corresponding tab index for the respective screen.

Document data

Additional data

Descriptions

Object links

Original

1-2-12 Display of the original document (display both originals from the document

overview for the order)

Path:

DOCUMENT

→

DISPLAY ORIGINAL DOCUMENT

1-2-13 Costs

Itemization

Analysis (Cost categories)

Path:

GOTO -> COSTS -> ITEMIZATION

→

ANALYSIS

3.16Order Structure and Order Processing Solutions

Unit: Order Structure and Order Processing

Topic: Order Structure and Order Processing

(LO215 Exercise 1)

4

SAP AG 1999

Order Creation/Order Change: Contents



Function procedure "Creating an order"



Automatic follow-on postings



Creation variants

 Normal

 With production version

 No reference to material (any activity)  Copy from order

 Related to sales order  With variant configuration



Bill of material and task list selection



Converting planned orders



Reading master data

4.2

SAP AG 1999

At the conclusion of this unit you will be able

to:

Order Creation/Changing Orders: Course

Objectives

 Define the basic features and variants for

creating production orders

 Describe subsequent functions in order

creation

 Describe the process of routing and BOM

selection when creating an order

 Define how master data is read into

existing orders

 Describe how to create and convert

planned orders

4.3

SAP AG 1999 Goods Receipt Goods Receipt

10

10

Confirmations Confirmations

9

9

Information Systems Information Systems

₁₂

₁₂

Settlement

Settlement,,ArchivingArchiving

and

andDeletionDeletion

11

11

Collective

CollectiveOrdersOrders

14

14

Mass Processing

Mass Processing

and Automation

and Automation

13

13

Material

MaterialStagingStaging

7

₇

Order

OrderStructureStructure//

Processing Processing

3

3

Order Control Order Control

₈

₈

Printing Printing Order

OrderDocumentsDocuments

6

6

Order Release Order Release

₅

₅

4

4

Introduction Introduction

₁

₁

Order

OrderCreationCreation // Order Change Order Change

Overview

Overview

₂

2

4.4

SAP AG 1999

Creating Production Orders

Friday July 27 1992 Tuesday December 18 1992 Manual

Manual Requirements planningRequirements planning AutomaticAutomatic

Specify order type Define order item

Copy routing

Copy bill of material

Lead time scheduling

Optional (Customizing)

Availability check

Add, change

Save production order Various functions (1)(1)

 The production order can be generated automatically (confirmation, sales order) or manually (directly)

by converting it from a planned order.

 A start / finish date is entered for the order item (product) according to the scheduling type (forwards or

backwards) .

 Lead time scheduling is executed automatically. It calculates the start / finish dates of the order and the

detailed dates and capacity requirements of the operations.

 You also have the option of carrying out an availability check (specifiable in Customizing).  You can determine the planned costs when saving the order (specifiable in Customizing).  ((11)) Other functions that can be executed automatically are:

4.5

SAP AG 1999

Automatic Postings

Material

Materialreservationsreservations

Purchase requisitions

Purchase requisitions

Costs

Costs(CO object)(CO object)

Capacity requirements

Capacity requirements

Transport

Transportrequirementsrequirements

Inspection lots Inspection lots PRT PRTrequirementsrequirements Inventory management Purchasing Controlling Capacity planning Warehouse management Quality management PRT management

 When you create a production order, a series of additional posting procedures occur at the time of

posting (the data is already formatted online).

These automatically generate the required data for stored parts of the system.

 Material reservations are generated for all warehouse components. You can choose whether these

reservations are to be immediately relevant to MRP or not until the time of release (indicator in the order-type dependent parameters T399X)

 Purchase requisitions are created for non-warehouse components and externally processed operations.  Costs are determined when you save.

 Transport requirements are generated when the operation is released.

 PRT requirements are only generated internally. At the present time, however, there is no

requirements planning for PRTs which works with these records.

Transaction CF21 (using PRT in orders) is available for evaluating PRT requirements in production orders.

4.6

SAP AG 1999

Creation Variants 1

20 50 100 Activity Directly (manually) From planned order Copy from order For sales order

From SD (assembly order) From confirmation

(rework)

As collective order

With variant configuration

Order header Order header Operations Material components Prod. resources/tools Planned Target Actual Costs

With reference to material

Without reference to material

4.7

SAP AG 1999

Creation Variants 2

Order Order Planned Planned _Order Material BOM Order Planned order Planned Create without routing and

bill of material

Create with routings

Create with routing and bill of material

Create with planned order

 Operations, material components and production resources / tools are normally copied from the routing

and BOM.

 You can also input such information manually.

 The BOM is not reread when you convert a planned order.

 If you do not specify otherwise in a routing, the system automatically assigns the BOM components to

4.8

SAP AG 1999

Own scheduling for planned orders To the day

Calculated basic dates Basic start date

Basic finish date Creation date

Base in-house production time or replenishment lead time Advantageous for performance

No capacity requirements are determined

Used

To the second

Starts from basic dates Requirements planning

Manual Determined production dates (scheduled dates)

Start date Finish date Release date Base operations

Determined capacity requirements

Material requirements planning

Lead time scheduling

Periods

O rder h ead er

Order h ead er Operati o ns

Mater ial com po ne nts Prod. res ource s/tool s Cost s Pla nn edT arget

Act ual 20 50 100

for orders and routings

Scheduling in Production Planning

 Production planning has two scheduling methods that are used differently and have different results:

 Scheduling of planned orders in material requirements planning (calculates the basic dates only)  Lead time scheduling (starts from the basic dates and calculates the production dates)

 Only lead time scheduling calculates operation-related dates and capacity requirements.  Lead time scheduling is the basis for

 Order scheduling  Routing scheduling

 Scheduling in applications PS, PM, PI

 In addition, lead time scheduling can be activated in material requirements planning in order to

4.9

SAP AG 1999

Order dates Operation dates Time concepts

PS Planned start date (basic start date) SS Production start date (scheduled start date) SF Production finish date (scheduled finish date) PF Planned finish date

AD Planned availability date LT Loading time

GI Goods issue date RDD Requested delivery date

ES Earliest start date LS Latest start date EF Earliest finish date LF Latest finish date

Lead time of order or operation

Execution time of operation Interoperation times Processing times in sales

Float

bef.prod. Op.0010 Op.0020 Op.0030 Op.0040 ... Op.0099 Float afterproduction GRproc.time Pick/packtime Loadingtime Transittime

PS SS

Queue

time Setuptime Proc. time Teardown Wait time Move time

SF PF AD LT GI RDD

ES LS EF LF

Float times for order/operation

Scheduling/Time Elements of an Order

 The slide shows all possible elements of the total lead time of a production order.  There are two order float times, which serve different purposes.

 Float before production - Postponement of dates, capacity planning

 Float after production - Absorbs any delays

 The order float can be predefined using a scheduling margin key (order header screen).

This key is entered in the material master and maintained in Customizing for Shop Floor Control by choosing "Scheduling".

 The duration of an operation is made up of a maximum of five time elements.

 Queue time  Setup time  Processing time  Teardown

 Minimum wait time

 The duration of the move time is the time between two operations but it is assigned to the preceding

operation.

 If a production order is being used to carry out production for a sales order (for example, assembly of a