CLL_PP Configuration Document

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Configuration Document SAP PP-PI Page 1 of 75 Version 1.0

Claris Lifesciences Ltd.

mySAP ERP ECC 6.0 Implementation

PP –PI Configuration Documentation

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Configuration Document SAP PP-PI Page 2 of 75 Version 1.0 Table Of Contents

1. PURPOSE OF THE DOCUMENT... 5

1.1 Purpose ... 5 2. PRODUCTION PLANNING... 6 2.1 Define MRP Controller ... 6 2.2 MRP Type ... 7 2.3 Lot Size... 8 2.4 Defining MRP Groups ... 9

2.5 Defining Special Procurement Type ...10

2.6 Define Scope of Planning for Total Planning ...11

2.7 Scheduling Parameters ...12

2.9 Define Scheduling Margin key ...13

2.10 Selection ID for BOM ...14

2.11 Defining BOM Explosion ...15

2.12 Define Number Ranges for Planned Independent Requirements ...16

2.13 Define Version Numbers ...16

2.14 Defining Strategy for MRP ...18

2.15 Define Strategy Group ...18

2.16 Define Planning Horizon ...19

2.17 Defining Availability of Stock ...20

2.18 Defining Rescheduling Check for Plant and MRP Group...21

2.19 Define Number ranges for Planning Run...22

2.20 Planning File Entry for Termination ...23

2.21 Maintain Rounding Profile ...24

2.22 Define Storage location MRP per plant ...25

2.23 Defining Parallel Processing for MRP ...26

2.24 Assigning MRP Checking Rule ...27

2.25 BOM Usage...28

2.26 Defining Item Categories ...29

2.27 Define Reasons for Variances...29

2.28 Define Number ranges for Manual Processing...30

2.29 Activating Requirements Planning...31

2.30 Defining Item Numbers of Order Types ...32

2.31 Defining Conversion Planned Order to Process Order ...33

3. PRODUCTION PLANNING FOR PROCESS INDUSTRIES...35

3.1 Define Resource Category ...35

3.2 Defining Person Responsible for Work Centre ...36

3.3 Standard Value Keys...37

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3.5 Defining Formula for Resources...39

3.6 Task List Usage...40

3.7 Define Capacity Planner...41

3.8 Define Number Ranges for Master Recipe...42

3.9 Recipe Status...43

3.10 Recipe Usages ...43

3.11 Define Planner Groups ...44

3.12 Control key for Master Recipe ...44

3.13 Define Capacity Categories ...45

3.14 BOM Status ...46

3.15 Process Order Type ...47

3.16 Number Ranges for Process Order ...47

3.17 Define Production Scheduler ...48

3.18 Define Production Scheduler Profile ...49

3.19 Scope of Check ...50

3.20 Define Checking Control ...51

3.21 Define Scheduling parameters for a process order...52

3.22 Defining Parameters for Order Confirmation ...53

3.23 Assigning Material Types to Task List ...54

3.24 Define Material Types Allowed for BOM Header...55

3.25 Defining Order Type-Dependent Parameters ...56

3.26 Assigning Process Instructions to Control Recipe Destinations ...57

4. BATCH MANAGEMENT...59

4.1 Activate Document Management for Batches ...59

4.2 Defining Batch Level...59

4.3 Activating Automatic Batch Number Assignment ...59

4.4 Maintain Internal Batch Number Assignment Range...60

4.5 Define Batch Creation for Production Order / Process Order ...60

4.6 Define Process Order Condition Tables ...61

4.7 Define Process Order Access Sequences ...61

4.8 Assign Search Procedure to Process Order and Activate Check...62

4.9 Activating batch-specific Unit of Measures ...63

4.10 Edit Batch-Specific Material Unit of Measure...63

4.11 Define Calculation of Proportion Quantity from Base Quantity ...64

4.12 Maintain Period Indicator ...64

4.13 Activating Expiration Date View per Plant...65

4.14 Define Process Order Strategy Types ...65

4.15 Define Search Procedure to Process Order...66

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4.17 Define Derivation Events ...67

5. DOCUMENT MANAGEMENT ...68

5.1 Define Number Ranges for Document Numbers ...68

5.2 Define Document Types ...69

5.3 Define Data Carrier...70

6. CLASSIFICATION SYSTEM ...72

6.1 Define Characteristics Groups ...72

6.2 Define Characteristics Status...73

7. OTHER SETTINGS...74

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1. PURPOSE OF THE DOCUMENT

1.1 Purpose

This document captures the required configurations details in SAP system to meet the business requirements as envisaged in the Design Stage (Business Blue Print Stage) for Project, Claris SAP Implementation Production Planning Module. The configuration steps have mappings to corresponding menu path to where the configuration has been done in the IMG (Implementation Guide).

The documentation provides visibility to all project teams members on the proposed system settings and changes. It is an important document for all future references in terms of system configuration. All future changes or updates to the system should be done based on this and the documentation updated accordingly.

This volume contains details on the configuration requirements for the Production Planning module for Claris Life Sciences pertaining to Master Data

This document should be read in conjunction with: 1. Process definition document

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2. PRODUCTION PLANNING

2.1 Define MRP Controller

Menu Path

Implementation Guide for R/3 Customizing (IMG)→_{Production → Material}

Requirements Planning → Planning → Check MRP Types Out Overall

Maintenance of Plant Parameters→ MRP Controller

Transaction Code OPPQ Configuration

Description

The MRP controller is a person or a group of persons responsible for monitoring material availability. MRP controller can be used to select the planning results per MRP controller.

Every material that is relevant to the planning run must be assigned to an MRP controller in the material master record.

For all the C&F’s and CA’s agents treated as Plants, the MRP Controller would be Z01. For Manufacturing Plants, it is detailed below. For all other plants, 001 MRP controller is named as “General”

Plant MRP Controller Description

101 RM Injectables 102 PPM Injectables 103 SPM Injectables 104 TPM Injectables 105 Production Inj. 106 Packing Inj. 107 Engineering Inj. 108 Lab Mat.Injectable 109 HK & Admin 1001 110 Captive Consumptn 101 RM Infusion 102 PPM Infusion 103 SPM Infusion 104 TPM Infusion 105 Production Inf. 106 Packing Inf. 107 Engineering Inf. 108 Lab Mat.Infusion 109 HK & Admin 1002 110 Captive Consumptn 101 RM API 102 PPM API 103 SPM API 104 TPM API 105 Production API 106 Packing API 107 Engineering API 108 Lab Mat. API 1003

109 HK & Admin 1004 101 Utility for Clarion

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2.2 MRP Type

Menu Path

Implementation Guide for R/3 Customizing (IMG)→_{Production → Material}

Requirements Planning → Master Data → Check MRP Types

Transaction Code SPRO Configuration

Description

MRP type to assign the procedure to be used to plan a material and to control, which MRP parameters can be, maintained for the material in the material master record. MRP type is assigned in the material master record

The following MRP Types are used for Claris MRP type Description

PD Normal MRP

VB Manual Reorder Level Planning ND No Planning

V1 Manual Reorder Level with External Requirements. M0 Master Production Scheduling

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2.3 Lot Size

Menu Path

Implementation Guide for R/3 Customizing (IMG) → Production → Material

Requirements Planning →_Planning→_{Lot-Size Calculation}→_Check Lot-Sizing procedure

Transaction Code OMI4 Configuration

Description

Lot-sizing procedures serve to calculate the procurement quantities, that is, the purchase order and production quantities

With the lot-sizing procedure we define how the order quantities are determined. A lot size defining the lot-sizing procedure is assigned to every material master record applicable to materials planning. The lot size is defined in Customizing by the combination of the lot-sizing procedure and the lot-sizing indicator.

Lot Size Key Description

EX Lot for Lot Order Quantity FX Fixed Order Quantity WB Weekly Lot Size MB Montly Lot Size

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2.4 Defining MRP Groups

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→

Materials Requirements Planning →_{MRP Groups}→_{Carry Out Overall} Maintenance of MRP Groups

Transaction Code OPPR Configuration

Description

In this step, we determine the MRP groups and we maintain the control parameters from a particular point of view. The MRP group groups certain materials together from the material requirements planning point of view to allocate them special control parameters for planning. These control parameters include the strategy group, the planning horizon and the creation indicator for the planning run selection of the Process Order type automatically.

Plant MRP

Group Description

1001 Demand for Domestic in Injectable

1002 Demand for Exports in Injectable

1003 In-house Production in Injectable

1004 In-house Packing in Injectable 1001

1005 External Procurement

1001 Demand for Domestic in Infusion

1002

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Configuration Document SAP PP-PI Page 10 of 75 Version 1.0 1003 In-house Production in Infusion

1004 In-house Packing in Infusion 1005 External Procurement 2000 2001 Traded Products

2002 Loan Licence

2.5 Defining Special Procurement Type

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→_Material

Requirements Planning →_{Master Data}→_{Define Special Procurement Type}

Description

In this step, we define the special procurement keys which as well as the procurement type control the procurement and storage of a material.

The special procurement type always refers to a procurement type.

We can , also define how the system treats the material as a component during the BOM explosion using control indicators.

Example 1 (special procurement keys without other indicators)

The procurement type "external procurement" is defined for raw materials. If a material is to be procured via a consignment order, you assign the special procurement type "consignment" to the material in the material master record. Example 2 (special procurement keys with other indicators)

A material appears in several BOMs as a component because it is assembled in finished products in in-house production. It is procured from an alternative plant

if no dependent requirements exist for the material.

The Special Procurement Keys are defined for the Manufacturing Plants and it has to be extended to the C&Fs, which are defined as plants

Plant Special Procurement Key Description

1001 ZB Stock transfer (Proc from 1002) 1001 ZC Stock transfer (Proc from 1003) 1002 ZA Stock transfer (Proc from 1001) 1002 ZC Stock transfer (Proc from 1003) 1003 ZA Stock transfer (Proc from 1001) 1003 ZB Stock transfer (Proc from 1002) 4500 ZD Stock transfer (Proc. From 4500) 2000 WA Stock transfer (Proc. From 2000)

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2.6 Define Scope of Planning for Total Planning

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→_Materials

Requirement Planning→_Planning→_{Define Scope of Planning for total} planning

Transaction Code OM0E Configuration

Description

In this IMG activity, we define the scope of planning and the sequence of the organizational units to be planned. These are either plants or, if we have converted MRP to MRP at MRP area level, the MRP areas that we plan together in a total planning run.

We enter the key for the planning run in the initial screen of the total planning run. The total planning run then carries out MRP for the plants or MRP areas defined in the scope of planning. we can enter as many plants or MRP areas as we like in the scope of planning. We can also only enter one MRP area. MRP is then only carried out for one MRP area. If we have activated MRP for MRP areas, when we enter a plant, this includes all MRP areas of this plant.

The Following Scope of planning has been defined for Claris Planning Scope Description

CFWH C & Fs and Wareshouse MFG Mfg plants

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2.7 Scheduling Parameters

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→_Capacity

Requirements Planning →_Operations→_Scheduling→_{Define scheduling} parameters for planned orders

Transaction Code OPU5 Configuration

Description

In this step we define the parameters for scheduling planned orders for each plant, order type and production scheduler. This comprises the following settings:

Scheduling levels (detailed-, production-rate and rough-cut scheduling) Date adjustment when deadlines are exceeded

Scheduling control for detailed scheduling Reduction

Scheduling parameters for planning scenarios for long-term planning/simulation

Scheduling Parameters for the Planned Orders are same for all the Plants as defined below: Parameters Values Detailed Scheduling Horizon 90 Rough Cut Scheduling Horizon 90

Scheduling Levels Via Detailed Scheduling

Adjust Dates Adjust basic dates, adjust dep reqmts to operation date For Capacity

Scheduling

Always basic dates, dep reqmts to operation dates Scheduling type Backwards

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2.9 Define Scheduling Margin key

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→_{Shop Floor}

control →_Operations→_Scheduling→_{Define Scheduling Margin key}

Description

Scheduling margin key specify time floats for scheduling as well as the release period for order release.

The following floats are defined:

Float before production: This is the time between the order start date and the scheduled start date.

Float after production: This is the time between the order finish date and the scheduled finish date.

The release date is calculated by adding the release period. The order release is carried out on this date.

The opening period represents the number of workdays that are subtracted from the order start date in order to determine the order creation date. The MRP controller uses this time as a float for converting planned orders into process orders.

The release period represents the number of workdays that are subtracted from the order start date in order to determine the process order release. The release period is only relevant for process order management.

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The following SMK are maintained for plants 1001, 1002 and 2000. For C&Fs, C&As treated as plants, the SMK are 000

Plant SMK Opening per Float Before Prd Float After Prd Release Peri

1001 Z00 000 000 000 000 Z01 001 000 000 000 Z02 000 001 001 000 Z03 000 001 002 000 Z04 000 001 003 000 Z05 000 001 004 000 1002 Z00 000 000 000 000 Z01 001 000 000 000 Z02 000 001 001 000 Z03 000 001 002 000 Z04 000 001 003 000 Z05 000 001 004 000 2000 Z01 003 000 000 000

2.10 Selection ID for BOM

Menu Path

Implementation Guide for R/3 Customizing (IMG)→_Production→_Material

Requirements Planning→_Planning→_{BOM Explosion}→_{Define BOM} Selection

Transaction Code SPRO

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Description selected during the planning run. Here, a sequence is usually determined which is used to select a valid BOM via the criterion "Usage".

For all the plants the selection id is set as 01

2.11 Defining BOM Explosion

Menu Path

Implementation Guide for R/3 Customizing (IMG)→_Production→_Material

Requirements Planning→_Planning→_{BOM Explosion}→_{Define BOM} Explosion Control

Transaction Code OMIW Configuration

Description

In this step, we specify the priority with which a BOM usage or routing usage is selected during the planning run. Here, a sequence is usually determined which is used to select a valid BOM via the criterion "Usage".

For all the plants the “Control Parameters for BOM Explosion” has been set as “ ” (BOM explosion number/order start date)

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2.12 Define Number Ranges for Planned Independent Requirements

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→_Production

Planning →_{Demand Management}→→→→_{Define number ranges for planned} independent requirements

Transaction Code OMID Configuration

Description

In demand management, number ranges are only used internally within the system for counting per planned independent requirements item. The number of the planned independent requirements is not displayed.

The Number Range is preset: 000000000001 to 9999999999999

2.13 Define Version Numbers

Menu Path

Implementation Guide for R/3 Customizing (IMG) →→→→_Production→→→→_Production

Planning→→→→_{Demand Management}→→→→_{Planned Independent requirements}→→→→ Define Version Numbers

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Transaction Code OMP2 Configuration

Description

In this step, we define versions to be able to:

differentiate between different planned independent requirements indicate the transfer of requirements from previous planning levels (for

example, the sales plan from SOP)

simulate requirements planning in long-term planning

We have maintained versions for all the twelve months of the year and for requirement plan

Requirement Plan Description

01 January version 02 February version 03 March version 04 April version 05 May version 06 June version 07 July version 08 August version 09 September version 10 October version 11 November version 12 December version

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2.14 Defining Strategy for MRP

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production_Material

Requirements Planning Master Data Independents Requirements Parameters Planning Strategy Define Strategy

Description

The planning strategy represents a procedure to be used for planning a material. It is defined by:

a requirements type from demand management, or a requirements type from sales order maintenance, or a combination of both that makes sense

The following strategy is being used

Strategy Description

10 Make to stock, used for Domestic Requirement PIR 11 Gross demand from C&F

40 Planning with final Assembly, used for International Sales order

2.15 Define Strategy Group

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production_Material

Requirements Planning Master Data Independents Requirements Parameters Planning Strategy Define Strategy Group

Description

The planning strategy represents an appropriate procedure to be used for planning and produced a material.

The Strategy Group available in standard SAP system will be used. To be Specific the below mentioned strategy will be used in CLARIS

For all the Non-repeat export products and domestic products with unique Secondary packing material requirements, PM requirements the Strategy

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group will be maintained as 40, for other materials at Manufacturing plants the strategy group will be maintained as 10, warehouse & at C&F’s strategy group is 11

Strategy Description

10 Make to stock, used for Domestic Requirement PIR 11 Gross demand from C&F

40 Planning with final Assembly, used for International Sales order

2.16 Define Planning Horizon

Menu Path

Implementation Guide for R/3 Customizing (IMG) → Production Material

Requirements Planning Planning MRP Calculation Define Planning

Horizon

Transaction Code OMDX Configuration

Description

The planning horizon is the period that is set for the "net change planning in the planning horizon." For this type of net change planning, only those materials are planned in the planning run that have a change relevant to MRP within the period (in work days).

The length of the planning horizon should at least include the following: Period in which customer orders enter

Delivery times

Complete material processing time

The Planning Horizon for all the Plants, C&Fs, C&As defined as Plants are maintained as 135 Work Days (Current Month 45 days + 3 Months - 90

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Working days)

2.17 Defining Availability of Stock

Menu Path

Requirements Planning →_Planning→_{MRP Calculation}→_Stocks→_Define Availability of Stock in Transfer/Blocked Stock/Restricted Stock

Description

In this step, we define whether stock in transfer (plant to plant) and/or blocked stock are included as well as restricted-use stock as available stock in the net requirements calculation.

Stock in transfer is the quantity that has already been withdrawn from the issuing plant (movement type, remove from storage - plant) but that has not yet been received by the receiving plant (movement type, place in storage - plant)

The system treats this stock as stock in transfer (plant to plant) for the receiving plant until the material is actually received and posted.

The Stocks, which will participate in the Net requirement Calculation, are Unrestricted Stock and Stock in Transit for all the plants and C&F defined as plants

For all the plants excepting clarion campus, Nourish, PKD, ICD and Head Office, blocked stocks are not included in the MRP calculation for Stocks.

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2.18 Defining Rescheduling Check for Plant and MRP Group

Menu Path

Requirements Planning →_Planning→_{MRP Calculation}→_Define Rescheduling Check

Transaction Code OMDW Configuration

Description

The rescheduling period represents the period in which the system checks whether the existing dates of the receipt elements that are no longer allowed to be changed automatically still suit the requirements situation. If the dates of these elements are no longer suitable, the system creates the following exception messages depending on the requirements situation

The Rescheduling checks for all the Plants and depot are identical as detailed below:

Parameters Value

Rescheduling horizon 100

Firm Planned Order Indicator Set Production Order Indicator Set Firm Purchase requisition Indicator Set Order item/Sch line Indicator Set QM inspection lot Indicator Set Shipping notification Indicator Set

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2.19 Define Number ranges for Planning Run

Menu Path

Requirements Planning →_{Number Ranges}→_{Maintain Number Ranges for} Planning Run

Description

In this step, we specify number ranges and intervals for the documents created during the planning run. These documents include:

Planned orders for operative planning

Planned orders for long-term planning (simulative planning) Dependent requirements and reservations Purchase requisitions

MRP lists

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2.20 Planning File Entry for Termination

Menu Path

Requirement Planning →_Planning→_{MRP Calculation}→_{Define Error} Processing in the Planning

Transaction Code OMDY Configuration

Description

In this step, we specify how the system is to proceed if errors occur during the planning run.

Maximum number of purchase order proposals per date. If we have selected a fixed or maximum lot size, the number of purchase order proposals created during the planning run is determined in lot sizing. If more purchase order proposals are created during the planning run than the upper limit specified here, the planning run is terminated for the material in question and a termination message appears

For Plant 1001 & 1002 The maximum Number of proposals have been defined as 999 and Sub MRP controller is 105. For all other plants this value is to set for 50 and sub MRP controller is 001

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2.21 Maintain Rounding Profile

Menu Path

Requirement Planning→_Planning→_{Lot-Size Calculation}→_Maintain Rounding profiles

Transaction Code OWD1 Configuration

Description

In this IMG activity, we define the rounding profile in order to adapt

the units of measure in material requirements planning to the delivery and transport units, for example, if purchase orders can only be delivered in bundles of 10 pieces.

With the rounding profile, we can define settings for rounding up/down order proposal quantities to deliverable quantities. There are two different types of rounding profiles; one for the core application and a rounding profile for Retail application:

· Statistical rounding profile for MRP in the standard system · Dynamic rounding profile and quantity to be

added/subtracted profile for Retail functions

The statistical rounding profile for MRP is made up of: · Level

· Threshold value · Rounding value

We can define several combinations of threshold and rounding values for a rounding profile. The individual combinations are then assigned a level.

The threshold value is the value from which the system rounds up to the next deliverable quantity. If the threshold value is not reached, the system rounds the quantity according to the next lower level. If the lowest level is not reached, then the system rounds up to a multiple of the rounding value, if the requirements quantity is larger than the threshold quantity. Otherwise, the requirements quantity remains unchanged. The rounding value is the value to which the system rounds the quantity if the threshold value is exceeded

The following Rounding profiles are maintained for Claris

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2.22 Define Storage location MRP per plant

Menu Path

Requirement Planning→_Planning→_{Define Storage location MRP per plant}

Description

In this step, we define the default values for storage location MRP (multi-plant). The indicator that we set here is proposed when creating a material master record for the storage locations maintained. If we have created a material for a storage location in the material master, for which we have maintained a proposal value.

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2.23 Defining Parallel Processing for MRP

Menu Path

Requirement Planning→_{Define Parallel Processing n MRP}

Transaction Code SPRO

Configuration Description

With the help of parallel processing procedures, we can significantly improve the runtime of the total planning run. To process in parallel, we can either select various sessions on the application server or various servers. The work package, with a fixed number of materials that are internally defined in the program, is distributed over the individual servers/sessions. Once a server/session has finished processing a package, it starts processing the next package. If a low-level code is being planned, the servers/sessions that have finished must wait until the last server/session has finished its package to avoid inconsistencies. Then the next low-level code is processed per packages. The parallel processing procedure is switched on in the initial screen of total planning.

The destination of parallel processing is maintained as CLSERDEV-CO_CDV_00

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2.24 Assigning MRP Checking Rule

Menu Path

Requirements Planning →_{Procurement Proposals}→_{Planned Orders}→_Define Availability Check for Components

Transaction Code OPPJ Configuration

Description

We control the availability check for requirements planning by defining the checking group and the checking rule at plant level or per MRP group. The availability check can be carried out in MRP for the dependent requirements. This means that the availability check can directly check whether sufficient material is available for the production of the assembly. The availability check is initiated from planned order processing. It is not carried out automatically in the planning run for each requirement of an assembly.

In the checking group, several checking rules are grouped together. Therefore, we can define different checking rules for different business application areas (sales and distribution, MRP, production orders, inventory management) or for different business operations. If we require different checking rules for different business operations, we can create several checking groups with the appropriate checking rules or we can assign another checking rule using the MRP group. The checking group is assigned to the material in the material master record, MRP 2 screen, in field "Availability check".

For all the manufacturing plant, the Check on the Material will be done during the Creation and Release of the Process Order. If there is material short falls No release will be carried out

The following checking rules are defined

Checking Rule Order Type

Z1 Checking Rule for Order Type C001 Z2 Checking Rule for Order Type C002 Z3 Checking Rule for Order Type C003 Z4 Checking Rule for Order Type C004 Z5 Checking Rule for Order Type C005

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2.25 BOM Usage

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→_{Basic Data} →_{Bill of Material}→_{General data}→_{Bill of Material Usage}

Transaction Code OS20 Configuration

Description

For one material separate bills of material for the individual organisational areas involved can be created. For example, you create separate BOMs for R&D, production, and costing. In this way, each area is dealing only with the specific data it requires.

Example:

The R&D BOM includes all the components of the product and their technical data from the design point of view. This BOM is generally not linked to any order.

The production BOM contains all the items required from the production and process point of view. Only items relevant to production, for which process data (such as the issue storage location) can be entered, are required. A production BOM does not contain any packaging materials required in the shipping department.

While defining a BOM usage, the configuration of the item status is defined. The item status is made up of a number of indicators in the BOM item (for example, "relevant to production", "relevant to engineering/design", and so on).

The item status controls how the BOM item is processed in related application areas.

For example, the production department requires a BOM with all the items that are relevant to production. These items are first copied to the planned order. When the planned order is converted to a process order, the items are copied to the process order. The process order tells the production department which materials and intermediates it has to produce.

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For Claris we have used the standard Usage as”1” for Production Usage Description

1 Production

2.26 Defining Item Categories

Menu Path

Implementation Guide for R/3 Customizing (IMG) Production Basic Data Bill of Material Item Data Define item categories

Description

When we enter a new BOM item, we must assign an item category to the item. The item category defines the attributes and functions of a BOM item. It controls field and screen selection for detail screens in BOM maintenance

The Following item categories are being used

Item category Description

N Non Stock Item

L Stock Item

K Class Item

D Document Item M Intra Material

2.27 Define Reasons for Variances

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→_{Shop Floor}

Control →_Operations→_Confirmation→_{Define Reasons for Variances}

Transaction Code OPK5

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Description The Reasons mentioned below are currently maintained at manufacturing plants 1001, 1002 (Injectable and infusion)

Variances

2.28 Define Number ranges for Manual Processing

Menu Path

Implementation Guide for R/3 Customizing (IMG) →→→→_Production→→→→_Materials

Requirement Planning→→→→_{Number ranges}→→→→_{Define Number Ranges for Manual} Processing

Description

In this step we maintain number ranges for Planned orders and Purchase requisitions

The SAP default values are used in our configuration for Planned orders

internal number range 1 with interval from 1 to 19999999

external number range 2 with interval from 20000000 to 29999999 for Purchase requisitions

internal number range 1 with interval from 10000000 to 19999999 external number range 2 with interval from 900000000 to 99999999

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2.29 Activating Requirements Planning

Menu Path

Implementation Guide for R/3 Customizing (IMG) →Production → Material

Requirements Planning → Planning File Entries → Activate MRP and Set Up

Planning File

Transaction Code OMDU Configuration

Description

We define the plants for which we want to carry out MRP here. Entries are only to be made in the planning file once this indicator has been set. This means: When creating a material, the material number is entered in the planning file and the system sets the total change indicator as well as the net change planning indicator

Every time the material undergoes a change relevant to the planning run, the system sets the total change indicator and/or the net change planning indicator (depending on the planning horizon).

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2.30 Defining Item Numbers of Order Types

Menu Path

Requirements Planning → Procurement Proposals → Conversion of

Procurement Proposals →_{Define Conversion of Planned Orders into} Purchase Requisitions

Transaction Code OMDV Configuration

Description

In this step, We define the following:

Number of planned orders, that are to be proposed for the collective conversion of planned orders into purchase requisitions

Item number of the item that is transferred to the purchase requisition during the conversion. Thus, it is possible to differentiate the purchase requisitions that were created in the planning run from the ones that were created manually by the purchasing department

For all the plants 500 has been proposed for the collective conversion of planned orders into purchase requisitions

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2.31 Defining Conversion Planned Order to Process Order

Menu Path

Requirements Planning → Procurement Proposals → Conversion of

Procurement Proposals → Define Order Type for Conversion to Production/Process Order

Transaction Code OPPE Configuration

Description

We define the order type that is automatically set when converting planned orders into production orders or process orders

For Plants 1001, 1002, Production order PP01 Standard production order & Process order PI01 Process order (internal number assignment) have been set for conversions

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3. PRODUCTION PLANNING FOR PROCESS INDUSTRIES

3.1 Define Resource Category

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_{Production Planning for}

Process Industries →_{Master Data}→_Resource→_{General Data}→_Define Resource Category

Transaction Code OP40 Configuration

Description

The resource category determines the data that can be maintained in a resource and, therefore, the functions (for example, costing or scheduling) for which the resource can be used.

Each resource category is assigned to the applications (for example, production, and plant maintenance or quality management) whose menus allow us to maintain resource with this category.

Each resource category has a number of screens assigned to it which the system displays when resource of this category are displayed. The screens contain groups of fields (for example, scheduling data). Depending on the resource category, we can make field selections on these screens (for example, defining required entry fields).

We specify whether change documents are written for each resource category. Line

Processing unit Team

Labor

Standard settings available in the system are used. The Resource Category used are 0008(Processing Unit)

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3.2 Defining Person Responsible for Work Centre

Menu Path

Process Industries →_{Master Data}→_Resource→_General→Determine Person Responsible

Description

With this key, we can identify a person or group of people responsible for maintaining the master data in certain work centers.

These employees are not responsible for planning tasks but only for the maintenance of the work center parameters

The following persons are responsible for maintaining work centre at Claris

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3.3 Standard Value Keys

Menu Path

Process Industries →_{Master Data}→_Resource→_{General Data}→_Standard

Value→_{Define Standard Value key}

Description

In this step we define standard value keys. The standard value key determines the meaning of the six standard values in the operation. The SAP System assigns a parameter ID to the standard values of the operation and the work in network activities.

The parameter ID in turn determines:

the key word displayed for the standard value on the screen, for example, setup, machine, labor, teardown etc.

the dimension (for example, time, quantity, volume) of the standard value

For Claris SAP Implementation we have defined “Z001” as Standard Value key

Key Description

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3.4 Defining Formula Parameters for Resources

Menu Path

Implementation Guide for R/3 Customizing (IMG) → Production Planning for

Process Industries →_{Master Data}→_Resource→_{Capacity Requirements}

Planning →_{Formulas for Resources (Work Centers)}→_{Define Formula} Parameters for Resources (Work Center)

Description

A formula is identified by its formula key. It is composed of formula parameters that are identified by parameter Ids.

The following parameters are maintained for Claris Life Sciences Parameter Description

SAPC04 Fixed Duration SAPC05 Lot Size dep. Duration SAP_03 Labour

SAP_09 Operation Quantity SAP_08 Base Quantity SAP_17 No. of Employees ZCL_01 Power

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3.5 Defining Formula for Resources

Menu Path

Implementation Guide for R/3 Customizing (IMG) → Production Planning for Process Industries → Master Data → Resource → Capacity Requirements Planning → Formulas for Resources (Work Centers) → Define Formula for

Resources (Work Center) Transaction Code OP17

We define the formulas that you want to use in the following areas: Capacity planning

Scheduling Costing

You can use the formula parameters to which values have been previously assigned. The formula parameters can be linked mathematically using the following operators:

Addition => + Subtraction => - Multiplication => * Division => /

Formula ZCL001 will be used in Machine dependent resources for scheduling and costing. Formula ZCL002 will be used in Labor dependent resources for costing. Formula ZCL003 will be used in Labor dependent resources for scheduling.

Formula

Key Description Formula

ZCL001

MACHINE DEPENDENT

SAPC04 + ( SAPC05 * SAP_09 / SAP_08 )

ZCL002

LABOR

DEPENDENT SAP_03 * SAP_09 / SAP_08 ZCL003

LABOR

DEPENDENT(SCH)

(SAP_03 * SAP_09 / SAP_08) / SAP_07

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3.6 Task List Usage

Menu Path

Process Industries →_{Master Data}→_Resource→_{General Data}→_Define Task List Usage

Description

Task List Usage key controls, that a resource can be used in which task lists like master recipe or PM task list. For example, we can categorize resource into maintenance resource or inspection resource according to their relevance and their usage in general task lists or inspection plans. We can also allow resource to be used in any combination of task lists types

Standard settings available in the system are used.

The following table lists the entries which are used for Claris Task list type Description

002 Only inspection plans 008 Master recipe + process order 009 All task list types

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3.7 Define Capacity Planner

Menu Path

Process Industries →_{Master Data}→_Resource→_{Capacity Requirement}

Planning →_{Determine Capacity Planner}

Description

Key for a group of employees who are responsible for capacity planning. We can use this key to select specific capacities. This is maintained at the client level.

The Following capacity Planners are maintained Plant MRP Controller Description

A01 INJ PRD LINE-1 A02 INJ PRD LINE-2 A03 INJ PRD LINE-3 A04 INJ PRD LINE-4 A05 INJ PRD LINE-5 A06 INJ PAC BELT-1 A07 INJ PAC BELT-2 A08 INJ PAC BELT-3 A09 INJ PAC BELT-4 A10 INJ PAC BELT-5 A11 INJ SPM PRINTING A12 INJ STERILIZATION A13 INJ DISP PM STORE

1001 B01 INF PRD LINE-1 B02 INF PRD LINE-2 B03 INF PRD LINE-3 B04 INF PRD LINE-4 B05 INF PRD LINE-5 B06 INF PRD LINE-6 B07 INF PRD LINE-7 B08 INF PAC BELT-1,2 B09 INF PAC BELT-3,4 B10 INF PAC BELT-5,6 B11 INF PAC BELT-7,8 B12 INF PAC BELT-9,10 B13 INF PAC BELT-11,12 B14 INF PAC BELT-13 B15 INF DISPENSING B16 INF SPM PRINTING B17 INF STERILIZATION

1002

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3.8 Define Number Ranges for Master Recipe

Menu Path

Process Industries →_{Master Data}→_{Master Recipe}→_{Setting for Task List}

Type →_{Define Number Ranges for Master Recipe}

Transaction Code C2N2 Configuration

Description

In this step we define number ranges for recipe groups. When a master recipe is created, it must be assigned to a recipe group, which is

identified using a group key

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3.9 Recipe Status

Menu Path

Process Industries →_{Master Data}→_{Master Recipe}→_{Data for Recipe Header} →_{Define Recipe Status}

Description

The recipe status determines:

Whether a recipe is released for use in process orders Whether a recipe is released for costing

Whether a consistency check is carried out before the recipe is posted

When a master recipe is created, a status must be assigned to it. This status can later be changed according to the processing stage of the recipe. Together with the recipe usage, the recipe status is used to create priority sequences that serve as a basis for the automatic selection of recipes during order creation, capacity planning and costing.

The following status are being maintained for Recipe Plant Description

1 Created

4 Released (general)

3.10 Recipe Usages

Menu Path

Process Industries →_{Master Data}→_{Master Recipe}→_{Data for Recipe Header} →_{Define Recipe Usage}

Description

The recipe usage determines:

The purpose or area, for which a recipe is created (for example, the chemical, the pharmaceutical or the food industry) The dynamic modification criteria to be used in the corresponding orders for adjusting the inspection scope if inspection points have not been defined When we create a master recipe, we must assign a recipe usage to it. We can create several recipes with different recipe usages for one material.

The standard usage available will be used

Usage Description

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3.11 Define Planner Groups

Menu Path

Process Industries → Master Data → Master Recipe → Data for Recipe Header →Define Planner Group

Description

A planner group identifies one or several planners who are responsible for Maintaining certain recipes in a plant. When we create or change a master recipe, we can assign a planner group to it.

The following planner group are being maintained for Claris Plant Planner Group Description

1001 A01 IPQA Manager - Injectable 1001 A02 Production Manager–Injectable 1002 B01 IPQA Manager – Infusion 1002 B02 Production Manager - Infusion

3.12 Control key for Master Recipe

Menu Path

Process Industries →_{Master Data}→_{Master Recipe}→_{Data for Operations}

and Phases →_{Define Control Keys}

Description

Control keys are assigned to operation and phases, and secondary resources. In the control key, we set a number of flags and keys that specify the business functions to be carried out for an operation, a phase or a secondary resource. Control key determines how an operation, phase, or secondary resource is handled in order processing and in product costing.

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Configuration Document SAP PP-PI Page 45 of 75 Version 1.0 Control keys can be used as follows:

In resources:

The control key we enter here is referenced or copied to the corresponding operations, phases and secondary resources of the master recipe.

In the master recipe

When creating operations and phases as well as when allocating secondary resources:

In the process order when maintaining operations, phases and secondary resources:

When we create a process order, the system copies the control keys we have maintained in the master recipe to the order. They can still be changed in the order if there is no reference to the resource.

For Claris we are maintaining the following control keys Control Key Control key Description

ZP01 Process manufacturing ZP02 QC : Scheduling and MIC ZP03 Process mfg., Inspection, AutoGR ZP04 QC : MIC only

ZP05 Process manufacturing with AutoGR ZP06 Process manufacturing-Bulk Preparation ZP07 QA : Scheduling

3.13 Define Capacity Categories

Menu Path

Process Industries→_{Master Data}→_Resource→_{Capacity requirement planning} →Define Capacity Categories

Description

In this step we define the capacity category that we want to assign to the resource. With capacity category we determine,

· which capacity type a capacity category belongs to, for example:

- "available capacity in volumes/quantity" for storage resources - "available capacity in time units" for processing units

· whether a capacity category can be assigned to people as single capacities We have used the Capacity category 008

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3.14 BOM Status

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_{ProductionPlanning for}

process Industries →_{Master Recipe}→_{Material List}→_{General Data}→_Define

BOM Status

Description

Via the BOM status, we define which other application areas can use a bill of material with this status.

In the different areas in a company (such as costing), the BOM is exploded according to the application. When we define an application for a certain area in the company, we select the status indicators in the Minimum requirements of BOM status dataset that the BOM status must have before the BOM is read for the BOM explosion.

In MRP, the following indicators are checked directly from the definition of the BOM status:

Explosion in MRP Released for orders

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3.15 Process Order Type

Menu Path

Process Industries →_{Process Order}→_{Master Data}→_Order→_{Define Order} Types

Transaction Code CORN Configuration

Description

Process order type covers control information that is needed for managing the order.

The order type defines the following:

We have to assign an order category to each order type. The order categories have fixed assignments in the SAP System and show the technical characteristics of the orders. The order category defines, for example, the transactions we can use to process an order.

Plant Order Type Description

1001 C001 Production C002 Packing C002 Validation C004 Performance Qualification C005 Repacking 1002 C001 Production C002 Packing C003 Validation C004 Performance Qualification C005 Repacking

3.16 Number Ranges for Process Order

Menu Path

Implementation Guide for R/3 Customizing (IMG) → Production Planning for Process Industries → Process Order → Master Data → Order →Number Ranges →Define Number Ranges for orders

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Transaction Code CO82 Configuration

Description

In this menu option, we define the number ranges for orders.

Each order is uniquely identified by an order number within one client.

We allocate each order to a number range group via the order type. We can allocate several order types to the same number range and thus the same interval.

• Internal number assignment

When we create an order, the SAP System automatically assigns a consecutive number from the number range that we have defined.

The number range defined are mentioned below Order Type Number Range

C001 1000000000-1099999999 C002 110000000- 1199999999 C003 120000000- 1299999999 C004 130000000- 139999999 C005 140000000- 1499999999

3.17 Define Production Scheduler

Menu Path

Process Industries →_{Process Order}→_{Master Data}→_Order→Bill of Material →_{Define Production Scheduler}

Transaction Code CORU Configuration

Description

Production scheduler is the entity who controls how process orders are managed. For every production scheduler, a production scheduler profile is attached. By assigning production schedulers to materials, we can define responsibilities for

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Configuration Document SAP PP-PI Page 49 of 75 Version 1.0 materials within production activity control.

In a production scheduling profile, we can Specify that in a process order particular business transactions be carried out in parallel.

Automatic batch creation on order creation. Batch creation on order release

For Claris we are marinating the following Production Scheduler Plant Production Scheduler Description

1001 101 Production

102 Packing

1002 101 Production

102 Packing

3.18 Define Production Scheduler Profile

Menu Path

Process Industries → Process Order → Master Data →Order →Bill of Material

→_{Define Production Scheduler Profiles}

Transaction Code CORY Configuration

Description

Production scheduling profile is linked to the Production Scheduler and one can: Specify automatic functions like order release on order creation Printing of Order

Scheduling on release

We can assign a production scheduler profile to a material (MMR) and production Scheduler (Customizing)

Scheduler profiles C001, C002, C003, C004 are maintained for plants 1001 and 1002

Plant Production Scheduler

profile Description

1001 C001 Production C002 Packing 1002 C001 Production

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3.19 Scope of Check

Menu Path

Implementation Guide for R/3 Customizing (IMG) → Production Planning for Process Industries → Process Order → Operations → Availability Check →

Define Scope of Check Transaction Code OPJJ

To check the availability of material components in the process order, the material components have to be assigned to checking group. Through checking group and checking rule the scope of check is defined. Through scope of check we can specify which MRP element to include and which stock categories to be included.

Define Scope of Check Yes / No (Include / Not Include)

Include safety stock Yes Stock in transfer No Include QI Stock No Include Blocked Stock No

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Configuration Document SAP PP-PI Page 51 of 75 Version 1.0 W/o Subcontracting No

Check without RLT Yes No Stor. Location Inspection No Checking period No Include Purchase orders No Include Purchase Indents No Include dependent reqmts No Include reservations No Include Sales Reqmts No Include deliveries No Include shipping notification No Include Dependent reservations No Include released Orders No Include Planned Orders No Include Production Orders No Include receipts in Past and future No

3.20 Define Checking Control

Menu Path

Process Industries →_{Process Order}→_Operations→_{Availability Check}→ Define Checking Control

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In this step we define the following:

Whether an availability check is to be carried out when we create or release an order

Whether an availability check is to be carried out when we save an order that has been created or released

Which checking rule is to be used

What effect a material shortfall is to have on the creation or release of an order

For all the manufacturing plant, the Check on the Material will be done during the Creation and Release of the Process Order. If there is material short falls No release will be carried out

3.21 Define Scheduling parameters for a process order

Menu Path

Implementation Guide for R/3 Customizing (IMG) →_Production→_Capacity

Requirements Planning →_Operations→_Scheduling→_{Define scheduling} parameters for planned orders

Transaction Code OPUZ Configuration

Description

The purpose of this activity is to define levels and control parameters for scheduling

It comprises maintenance of

scheduling levels (detailed-, production-rate and rough-cut scheduling) date adjustment when deadlines are exceeded

scheduling control for detailed scheduling reduction

For all the Plants and Order types the scheduling has been defined as forwards