TSCM42

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TSCM42

Planning & Manufacturing II

SAP SCM Date Training Center Instructors Education Website

Participant Handbook

Course Version: 95 Course Duration: 10 Days Material Number: 50099845

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

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Course Overview ... ix

Course Goals ... ix

Course Objectives ... x

Unit 1: Introduction... 1

Overview of the Training for Solution Consultant SCM Planning & Manufacturing...2

Production types of the applications SAP ERP and SAP SCM ...6

Unit 2: Production Orders: Introduction ... 15

Order-Controlled Production Using Production Orders ... 16

Unit 3: Order Processing and Order Structure... 33

Order Processing (Overview) ... 34

Order Structure... 46

Unit 4: Order Creation ... 79

Order Creation ... 81

Master Data Selection...106

Scheduling ...136

Costing ...150

Unit 5: Availability Check, Capacity Planning, and Order Release ... 157

Availability Checks ...158

Capacity Planning...183

Order Release ...198

Unit 6: Printing Order Documents ... 215

Print Control, Standard Documents and Prerequisites (Overview) ...216

Printing Production Orders ...222

Unit 7: Material Staging and Withdrawal ... 241

Material Staging ...242

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Unit 8: Confirmations ... 271

Procedure, Prerequisites and Effects (Overview) ...272

Execution of Confirmations ...281

Unit 9: Goods Receipt ... 303

Prerequisites of Goods Receipts...304

Goods Receipt Posting...309

Unit 10: Order Settlement, Archiving and Deletion ... 321

Order Settlement ...322

Archiving and Deleting ...333

Unit 11: Information Systems, Mass Processing and Automation ... 349

Information Systems...350

Automation and Mass Processing ...353

Collective Orders...358

Trigger Points...362

Unit 12: Optional Appendix: Further Functions and Enhancements ... 365

Order Split ...367

Shift Reports / Shift Notes ...392

Work-in-Process (WIP) Batch ...435

XSteps for Routings and Production Orders ...465

PP-PDC Interface ...488

SAP MII in Shop Floor Control ...493

Handling Units in Production ...497

Unit 13: Order-Controlled Production with Process Orders .. 501

Order-Controlled Production with Process Orders ...502

Elements, Functions, and Processing of a Process Order ...513

Unit 14: Repetitive Manufacturing ... 569

Characteristics of Repetitive Manufacturing...570

Functions and Process Steps in Repetitive Manufacturing...587

Unit 15: KANBAN ... 627

Features of the KANBAN Procedure ...628

The KANBAN Procedure...632

Unit 16: Capacity Requirements Planning (ERP) ... 651

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Capacity Evaluation ...656

Capacity Leveling in the Tabular Planning Table ...672

Available Capacity ...684

Capacity Leveling in the Graphical Planning Table...688

Appendix 1: Summary ... 709

Appendix 2: Detailed Functions of Capacity Requirements Planning ... 713

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Production is part of the applications SAP ERP (Enterprise Resource Planning) and SAP SCM (Supply Chain Management) in the SAP Business Suite. You can use this to manage all the production activities within your supply chain in one integrated system, from planning through execution to analysis. The focus of this course is execution. The following topics are dealt with in particular:

• Order-Controlled Production with Production Orders • Order-Controlled Production with Process Orders • Repetitive manufacturing

• KANBAN

• Capacity Requirements Planning (ERP) Information on SAP software components

The information in this course is based on the following SAP software components and releases:

• SAP ERP 6.0 Enhancement Package 5 • SAP SCM 7.0 Enhancement Package 1

Target Audience

This course is intended for the following audiences:

• Application consultants responsible for the implementation of shop floor control as part of the applications of SAP Business Suite

Course Prerequisites

Required Knowledge

• TSCM40 Planning & Manufacturing I

• Additional e-learning products (see graphic in unit “Introduction”) Recommended Knowledge

• SAPSCM: SCM Overview

• PLM100 Lifecycle Data Management • SCM100 Planning Overview (ERP) • SCM200 Planning Overview (SCM)

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Course Goals

This course will prepare you to:

• Understand the positioning, integration, and functions of the production area within the SAP ERP (Enterprise Resource Planning) and SAP SCM (Supply Chain Management) solutions

• Get an overview of the supported production types and Capacity Requirements Planning (ERP)

Course Objectives

After completing this course, you will be able to:

• Describe basic shop floor control procedures and functions and understand simple scenarios in the SAP System

• Use capacity planning functions for your consulting activities

SAP Software Component Information

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

• ERP 6.0 Enhancement Package 5 • SAP SCM 7.0 Enhancement Package 1

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Unit 1

Introduction

Unit Overview

In this unit, you will learn about the production types of the SAP ERP and SAP SCM applications within the SAP Business Suite.

Unit Objectives

After completing this unit, you will be able to:

• Obtain an overview of the scope of the training

• you will be able to name the production types that are supported within the SAP Business Suite.

Unit Contents

Lesson: Overview of the Training for Solution Consultant SCM Planning & Manufacturing ...2 Lesson: Production types of the applications SAP ERP and SAP SCM ...6

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Lesson: Overview of the Training for Solution Consultant

SCM Planning & Manufacturing

Lesson Overview

Overview of the Training for Solution Consultant SCM Planning & Manufacturing

Lesson Objectives

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

Business Example

None

Basic Training

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

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

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

The training course also contains a case study, which allows you to make practical use of the knowledge you acquired by configuring specified integrated business processes. At the end of the course, participants take an exam for certification as a Solution Consultant SCM - Planning/Manufacturing with SAP ERP.

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Figure 1: Basic Training: Consultant Profile SAP SCM - Planning & Manufacturing (for New Consultants)

Alternative Project Team Training

The training material of the Consultant Academy is largely based on the relevant standard training, but is supplemented by topics that are relevant for consultants. The following table shows which topics were taken from the standard training and which topics are discussed additionally:

Consultant Academy Training Course

Course Content TSCM40 (Planning/Manufacturing

I)

5 days PLM114 (Basic Data)

or 2 days PLM110 (Basic Data, Part 1) and 3 days PLM111 (Basic Data, Part 2)

5 days SCM240 (Production Planning (ERP))

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

5 days SCM310 (Production Orders)

2 days Process Manufacturing, Repetitive Manufacturing, and KANBAN from SCM300

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0.5 days SCM360 (Capacity Planning (ERP))

2.5 days Integrated Case Study 3 hours Certification Exam

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Lesson Summary

You should now be able to:

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Lesson: Production types of the applications SAP ERP

and SAP SCM

Lesson Overview

In this lesson, you will learn about the production types that are supported within the SAP Business Suite.

Lesson Objectives

After completing this lesson, you will be able to:

Business Example

Your company implements the SAP Business Suite. You are either a member of the project team responsible for implementing the shop floor control functions or you are in the production department. You use various scenarios to gain an overview of the possibilities and functions of the supported production types.

Overview of SAP applications

Figure 2: SAP ERP Application Overview

As part of the long-term product strategy of SAP, you are offered an SAP Business Suite that comprises a number of applications.

The Enterprise Resource Planning (ERP) application is a comprehensive application that enables a company to efficiently plan, control and monitor complex delivery, procurement and production networks.

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This application supports a synchronized and close interaction between all departments involved (and all people involved) within a logistics chain.

Customers, sales, production planning, manufacturing, warehouse management, purchasing, and vendors are all included in this complete solution.

The SAP ERP application includes a number of areas (see above).

You will find further information about the individual components of the SAP ERP application at

http://www.sap.com/solutions/businessmaps/solutionmaps/ and also here, under Cross-Industry Business Maps.

Figure 3: SAP SCM Application Overview

SAP Supply Chain Management (SCM) is a comprehensive application that enables a company to efficiently plan, implement and monitor complex delivery, procurement and production relationships (supply chains). This application supports a synchronized and close interaction between all departments involved (and all people involved) in a logistics chain.

Customers, sales, production planning, manufacturing, warehouse management, purchasing, and vendors are all included in this complete solution.

In particular, the processing of cross-company processes and the collaborative planning and procurement processes, which also enable a connection to open market places, are a main feature of this application.

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The SAP SCM application includes a number of areas (see above).

You will find further information about the individual components of the SAP SCM application at

http://www.sap.com/solutions/businessmaps/solutionmaps/ and also here, under Cross-Industry Business Maps.

Figure 4: SAP Components

In-house production is largely supported by the SAP component SAP ECC (formerly R/3).

SAP SCM provides considerably enhanced planning tools (Advanced Planning and Optimization (APO), an enhanced inventory function (Supply Network Collaboration (SNC)) and Event Management (EM).

SAP BW (Business Information Warehouse) is used to separately store data for variable evaluations.

Interfaces for realizing the integration of ECC with SCM, BW or CRM are provided with an appropriate plug-in.

The interface between ECC and SCM (APO) is called a Core Interface (CIF). Sales orders can be managed using the component SAP CRM, but can be managed in SAP ECC also.

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Production Types

Depending on the manufacturing process, product complexity, stability of production, and other criteria, a company has various requirements with regard to shop floor control.

For this reason, the SAP ERP and SAP SCM applications support a variety of production types.

Figure 5: Production Types (1)

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Lesson Summary

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Unit Summary

• Obtain an overview of the scope of the training

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Test Your Knowledge

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Answers

1. Name the production types that are supported within the SAP Business Suite.

Answer:

• Order-related production with production order • Order-related production with process order • Repetitive manufacturing:

– Period and quantity-oriented production • Kanban:

– Replenishment-controlled using stock transfer, external

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Unit 2

Production Orders: Introduction

Unit Overview

• Order-controlled production using production orders – Application areas

– Characteristics – Process flow – Master data

Unit Objectives

After completing this unit, you will be able to:

• Explain the characteristics of order-controlled production using production orders

• Describe the cross-application process flow

• Name the master data required for production orders

• Show the logistics process ranging from planning to production order creation in a simple application example in the ECC system

Unit Contents

Lesson: Order-Controlled Production Using Production Orders... 16 Exercise 1: Demand Planning ... 25 Exercise 2: Material Requirements Planning ... 27 Exercise 3: Production Order Creation ... 29

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Lesson: Order-Controlled Production Using Production

Orders

Lesson Overview

This lesson provides you with an overview of the characteristics of order-controlled production using production orders.

Lesson Objectives

Business Example

You familiarize yourself with

• The cross-application process flow

• The master data required for production orders

In a simple application example, you show the logistics process ranging from planning to production order creation in a simple application example in the ECC system.

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Figure 7: Manufacturing: Production Types

Depending on the manufacturing process, production infrastructure, product complexity, stability of production, and further criteria, a manufacturing company has various requirements with regard to shop floor control.

Correspondingly, various production types are supported.

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Production orders are used in a variety of industries and industrial sectors. Production orders can be used in a number of production types.

These production types are essentially dependent of the product stability, product complexity and the manufacturing processes used.

Figure 9: Definitions in the Production Order

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Figure 11: Order-Related Production: Characteristics (2)

A number of functions are available for production orders, which allow for complex support of production (see the following graphics).

The SCM310 course covers all the basic functions and a selection of the most important enhanced functions in detail.

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The PP-PDC (Plant Data Collection) interface is a widespread interface specially designed for production orders. Its content focuses on the data exchange between the SAP ECC system and standard plant data collection systems (PDC).

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Execution Steps (XSteps) are used for the variable description of process instructions and messages in the production order. They are the basis on which data can be exchanged with the process control level (downloading control

instructions and uploading process messages) and interactive work instructions

generated for the machine operator.

SAP ODA (Online Data Access) supports the data exchange between SAP ECC and process control systems from different manufacturers in the area of industrial production and is based on the OPC standard - Open connectivity in

industrial automation:

• This is a manufacturer-independent standard interface for systems in the production area, which is used mainly in process automation.

• The task of an OPC server is to supply OPC clients (for example, the SAP ECC system) with data from a wide variety of systems installed at the process level. Typical examples include: PLC (Programmable Logic Controller), SCADA (Acronym for Supervisory Control and Data Acquisition), DCS (Distributed Control System), HMI (Human- Machine Interface)

• You can learn more about OPC under: http://www.opcfoundation.org/ SAP MII (Manufacturing Integration & Intelligence) is an independent SAP software component and enables real-time data integration in Manufacturing Execution Systems (MES) by means of standardized, preconfigured connectors.

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Figure 16: Cross-Application Process Flow

Production order management is a central part of a complex process chain starting with an independent requirement (planned or customer requirement) and ending with the goods receipt of a finished product.

Production order management controls the whole process of in-house production of products and is integrated in the functions of capacity requirements planning, costing and inventory management. Furthermore there are links or interfaces to quality management as well as external systems of process control.

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Master Data for Production Orders

Figure 17: Master Data for Production Orders

The material to be produced must have the procurement type in-house production (X, E).

The material status must be released for production at cross-plant level (MARA) as well as at 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. The work scheduling view must be created (mandatory).

You prepare BOMs as single level BOMs. A special selection procedure chooses the valid BOM.

You maintain standard routings as routings. A special selection procedure chooses the valid routing.

Work centers are assigned to the operations in the routing.

Production resources/tools are assigned to the operations in the routing. Documents (managed in the document management system) can be linked with the production order and displayed there.

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Exercise 1: Demand Planning

Exercise Objectives

After completing this exercise, you will be able to: • Create planned independent requirements.

Business Example

You create planned independent requirements for a material and display the result in the stock/requirements list.

Task:

You create planned independent requirements for the material T-SCM372-PP-## and display them in the stock/requirements list.

1. Choose transaction MD61

(SAP menu: Logistics → Production → Production Planning → Demand

Management → Planned Independent Requirements → Create) to create the

following planned independent requirements:

Material: T-SCM372-PP-## Plant: 1000

Define in the Planning Table quantities of 10 PC for the next month and the month after the next.

Save your planned independent requirements. 2. Choose transaction MD04

Management → Environment → Stock/Requirements List) to display the

stock/requirements list for:

The list contains the planned independent requirements for material T-SCM372-PP-## together with the requirement quantities and requirement dates.

It also provides information on the quantities that are available today and on the requirements dates.

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Solution 1: Demand Planning

Task:

You create planned independent requirements for the material T-SCM372-PP-## and display them in the stock/requirements list.

Management → Planned Independent Requirements → Create) to create the

following planned independent requirements:

Define in the Planning Table quantities of 10 PC for the next month and the month after the next.

Save your planned independent requirements. a)

-2. Choose transaction MD04

Management → Environment → Stock/Requirements List) to display the

stock/requirements list for:

The list contains the planned independent requirements for material T-SCM372-PP-## together with the requirement quantities and requirement dates.

It also provides information on the quantities that are available today and on the requirements dates.

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-Exercise 2: Material Requirements

Planning

Exercise Objectives

After completing this exercise, you will be able to: • Perform a planning run.

• Evaluate the planning result.

Business Example

You will run material requirements planning for your material and display the resulting planned orders in the stock/requirements list.

Task:

You carry out a multilevel single-item planning for your material T-SCM372-PP-## and display the resulting planned orders in the stock/requirements list.

(SAP menu: Logistics → Production → MRP → Planning → Multilevel

Single-Item Planning) to carry out a multilevel single-item planning run for:

You don’t have to set or change any planning parameters. Press Enter twice to start the planning run.

(SAP menu: Logistics → Production → MRP → Evaluations →

Stock/Requirements List) to display the stock/requirements list for:

As a result of the MRP run, the system created planned orders to cover the planned independent requirements.

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Solution 2: Material Requirements

Planning

Task:

You carry out a multilevel single-item planning for your material T-SCM372-PP-## and display the resulting planned orders in the stock/requirements list.

(SAP menu: Logistics → Production → MRP → Planning → Multilevel

Single-Item Planning) to carry out a multilevel single-item planning run for:

You don’t have to set or change any planning parameters. Press Enter twice to start the planning run.

a)

-2. Choose transaction MD04

(SAP menu: Logistics → Production → MRP → Evaluations →

As a result of the MRP run, the system created planned orders to cover the planned independent requirements.

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-Exercise 3: Production Order Creation

Exercise Objectives

After completing this exercise, you will be able to: • Perform a planned order conversion.

Business Example

You will convert one of your planned orders to a production order.

Task:

You convert one of your planned orders to a production order in the stock/requirements list.

(SAP menu: Logistics → Production → Shop Floor Control → Control →

2. Double-click the MRP element PlOrd for the first planned order.

Choose button → Prod.Ord. in the dialog box Additional Data for MRP

Element.

The planned order will be converted to a production order. Save your production order.

After saving, the stock/requirements list appears again. Choose the Refresh icon.

The new production order is displayed as a new MRP element. The order number is displayed in the data on the MRP element. The original planned order was deleted after the conversion.

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Solution 3: Production Order Creation

Task:

You convert one of your planned orders to a production order in the stock/requirements list.

a)

-2. Double-click the MRP element PlOrd for the first planned order.

Choose button → Prod.Ord. in the dialog box Additional Data for MRP

Element.

The planned order will be converted to a production order. Save your production order.

The new production order is displayed as a new MRP element. The order number is displayed in the data on the MRP element. The original planned order was deleted after the conversion.

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-Lesson Summary

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Unit Summary

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Unit 3

Order Processing and Order Structure

Unit Overview

• Production order processing

• Production order structure and elements • Production order screens and data

Unit Objectives

After completing this unit, you will be able to: • Describe production order processing.

• Describe the structure and elements of a production order.

• Navigate in the production order and explain the most important screens and their content.

Unit Contents

Lesson: Order Processing (Overview) ... 34 Exercise 4: Production Order Processing ... 37 Lesson: Order Structure ... 46 Exercise 5: Production Order Structure ... 57 Exercise 6: Order Creation Without Master Data ... 69

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Lesson: Order Processing (Overview)

Lesson Overview

This lesson informs you about production order processing.

Lesson Objectives

After completing this lesson, you will be able to: • Describe production order processing.

Business Example

You release a production order, post the good issues, confirm the order, and finally post the goods receipt.

Figure 18: Processing Flow of a Production Order

The production order goes through many individual activities.

Many of these activities can run automatically or in the background, so that the effort required to process orders manually is minimized.

A number of settings available in Customizing allow you to successfully perform each step in order processing.

In the SCM920 training course, you are shown how to make and test these Customizing settings.

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(1) These functions can be automated by means of Customizing.

(2) These functions can be executed by means of background processing. WIP determination, variance calculation, and settlement are generally periodic work for Cost Object Controlling ("COC"), and are usually processed in the background.

The quality management (QM) tools can be used during the production process and at the time of the goods receipt.

Various interfaces for process integration are available for downloading orders and uploading process messages.

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Exercise 4: Production Order Processing

Exercise Objectives

After completing this exercise, you will be able to: • Release a production order.

• Post goods issues.

• Confirm a production order. • Post a goods receipt.

• Execute a production order using the functions of process integration.

Business Example

You release a production order, post the good issues, confirm the order, and finally post the goods receipt.

In an alternative scenario you also test the execution of a production order using the functions of process integration.

Task 1:

You release your production order for material T-SCM372-PP-##, post the good issues, confirm the order, and finally post the goods receipt.

2. Double-click the MRP element PrOrd.

Choose icon Change Element in the dialog box Additional Data for MRP

Element.

Choose icon Release Order in the production order. Save your production order.

The production order is marked as released. 3. Choose transaction MB1A

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(SAP menu: Logistics → Production → Shop Floor Control → Goods

Movements → Goods Issue) to post the goods issues for your production

order.

Choose button To Order… Pop up Reference: Order: Order: <order number>

Check the proposed materials and quantities and post the goods issues. 4. Choose transaction CO15

(SAP menu: Logistics → Production → Shop Floor Control → Confirmation

→ Enter → For Order) to confirm your production order.

Order: <order number>

Confirmation Type: Auto. Final Conf. Check and accept the proposed Yield to conf.. Save the confirmation.

5. Choose transaction MB31

Movements → Goods Receipt) to post the goods receipt for your production

order.

Movement Type: 101 Order: <order number> Plant: 1000

Check the proposed material and quantity and post the goods receipt. 6. Check the actual situation for your material T-SCM372-PP-## in the

stock/requirements list.

Your production order has been removed from the list. The Available Qty has been increased from 0 to 10 PC as a result of the goods receipt.

Task 2:

In an alternative scenario you also test the execution of a production order for your material T-SCM372-PP-## using the functions of process integration.

1. Enter the stock/requirements list for material T-SCM372-PP-##. Convert the remaining planned order to a production order. Release the production order.

Choose the Generate Control Instructions icon to generate the control instructions for your production order.

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Save your production order. 2. Choose transaction CO53XT

(SAP menu: : Logistics → Production → Shop Floor Control → Process

Integration → Control Instructions → Monitor Control Instructions/Recipes)

to enter the control instruction monitor.

Select the control instruction for your production order:

Plant: 1000

Manufacturing order:

<number of your production order>

3. In the monitor, select your control instructions and choose Send.

To check whether the control instructions have been sent, choose Update if necessary.

The control instructions should have Sent status. 4. Choose transaction CO60XT

(SAP menu: Logistics → Production → Shop Floor Control → Process

Integration → Work Instructions → Find) to find the work instructions for

your production order. Select your work instructions:

Plant: 1000

Manufacturing order: <number of your production order>

5. Access the work instructions for the Work Center 1 operating group in change mode and maintain the work instruction.

Report the start of your work instruction with your digital signature. Sign with your SAP user ID and your SAP password.

The signature triggers the creation a SAP standard process message of type PP_OPST to post a time event confirmation for the start of the first operation 0010.

In a material list you find the components required for operation 0010. A SAP standard process message of category PP_CONS will be created for each component to post the goods issues.

At last, report the end of your work instruction with your digital signature. The signature triggers the creation a process message of type PP_OPST to post a time event confirmation for the end of the first operation 0010.

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Complete your work instruction.

6. Choose transaction CO54XT

Integration → Process Messages → Message Monitor) to enter the process

message monitor.

Select the process messages for your production order:

Plant: 1000

Order: <number of your production order>

7. In the monitor, select your process messages and choose Send Message. The messages of type PP_OPST post the start and the end of operation 0010 with time event confirmations.

The messages of type PP_CONS post goods issues for the two components. The message of type PI_CRST posts the completion of the work instruction. 8. Optional:

You could check now the results of the maintenance of your work instruction and the sending of your process messages in your production order.

Display your production order and check e.g. the header status and the operation status for operation 0010, the confirmed dates for operation 0010, the withdrawal quantities for the material components, the cost analysis, and the list of documented goods movements.

A goods receipt could be posted by a process message of type PP_PROD in your last work instruction for the Work Center 5 operating group.

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Solution 4: Production Order Processing

Task 1:

You release your production order for material T-SCM372-PP-##, post the good issues, confirm the order, and finally post the goods receipt.

a)

-2. Double-click the MRP element PrOrd.

Choose icon Change Element in the dialog box Additional Data for MRP

Element.

Choose icon Release Order in the production order. Save your production order.

The production order is marked as released. a)

-3. Choose transaction MB1A

Movements → Goods Issue) to post the goods issues for your production

order.

Choose button To Order… Pop up Reference: Order: Order: <order number>

Check the proposed materials and quantities and post the goods issues. a)

-4. Choose transaction CO15

(SAP menu: Logistics → Production → Shop Floor Control → Confirmation

→ Enter → For Order) to confirm your production order.

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Confirmation Type: Auto. Final Conf. Check and accept the proposed Yield to conf.. Save the confirmation.

a)

-5. Choose transaction MB31

Movements → Goods Receipt) to post the goods receipt for your production

order.

Movement Type: 101 Order: <order number> Plant: 1000

Check the proposed material and quantity and post the goods receipt. a)

-6. Check the actual situation for your material T-SCM372-PP-## in the stock/requirements list.

Your production order has been removed from the list. The Available Qty has been increased from 0 to 10 PC as a result of the goods receipt. a)

-Task 2:

In an alternative scenario you also test the execution of a production order for your material T-SCM372-PP-## using the functions of process integration.

1. Enter the stock/requirements list for material T-SCM372-PP-##. Convert the remaining planned order to a production order. Release the production order.

Choose the Generate Control Instructions icon to generate the control instructions for your production order.

Save your production order. a)

-2. Choose transaction CO53XT

(SAP menu: : Logistics → Production → Shop Floor Control → Process

Integration → Control Instructions → Monitor Control Instructions/Recipes)

to enter the control instruction monitor.

Select the control instruction for your production order:

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Plant: 1000 Manufacturing

order:

<number of your production order>

a)

-3. In the monitor, select your control instructions and choose Send.

To check whether the control instructions have been sent, choose Update if necessary.

The control instructions should have Sent status. a)

Integration → Work Instructions → Find) to find the work instructions for

your production order. Select your work instructions:

Plant: 1000

Manufacturing order: <number of your production order>

a)

-5. Access the work instructions for the Work Center 1 operating group in change mode and maintain the work instruction.

Report the start of your work instruction with your digital signature. Sign with your SAP user ID and your SAP password.

The signature triggers the creation a SAP standard process message of type PP_OPST to post a time event confirmation for the start of the first operation 0010.

In a material list you find the components required for operation 0010. A SAP standard process message of category PP_CONS will be created for each component to post the goods issues.

At last, report the end of your work instruction with your digital signature. The signature triggers the creation a process message of type PP_OPST to post a time event confirmation for the end of the first operation 0010.

Complete your work instruction.

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Integration → Process Messages → Message Monitor) to enter the process

message monitor.

Select the process messages for your production order:

Plant: 1000

Order: <number of your production order>

a)

-7. In the monitor, select your process messages and choose Send Message. The messages of type PP_OPST post the start and the end of operation 0010 with time event confirmations.

The messages of type PP_CONS post goods issues for the two components. The message of type PI_CRST posts the completion of the work instruction. a)

-8. Optional:

You could check now the results of the maintenance of your work instruction and the sending of your process messages in your production order.

Display your production order and check e.g. the header status and the operation status for operation 0010, the confirmed dates for operation 0010, the withdrawal quantities for the material components, the cost analysis, and the list of documented goods movements.

A goods receipt could be posted by a process message of type PP_PROD in your last work instruction for the Work Center 5 operating group.

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-Lesson Summary

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Lesson: Order Structure

Lesson Overview

This lesson informs you about the data structure for a production order.

Lesson Objectives

• Describe the structure and elements of a production order.

• Navigate in the production order and explain the most important screens and their content.

Business Example

You analyze the data structure of a production order: • You will learn how to navigate in the order.

• You will get an overview of which information can be found on which screens.

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Figure 21: Elements of a Production Order

A production order has the order structure mapped.

A standard sequence of operations may have other (parallel, alternative) operation sequences.

You can make a selection from several alternative sequences.

The standard sequence must have at least one operation. If necessary, the system creates the operation itself.

You can choose whether to assign material components, production resources/tools and trigger points to the operation.

Suboperations are permitted within an operation.

You can link documents in the DMS (drawings, text files, images,….) to the production order (as of release 4.6).

Execution steps are any process instructions (print, temperature, texts, …) that can be transferred to any destination (control instruction in SAP ECC, process control computer, CNC engine) in the form of a control instruction using the functions of process integration (as of release 6.0 EhP3).

Costs are determined at operation level, managed at order header level and a settlement rule is created for the orders for order-related COC only (optional as of release 4.5).

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Figure 22: Production Order – Header

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 number of single 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.

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Figure 23: Production Order – Operation

This segment of the operation describes the individual work steps of the production order.

There are several single screens for an operation. These screens include other detail screens. For example, the component overview branches to screens for each material component.

You can add a hierarchy of sub-operations to an operation. This is used for detailed calculation and capacity planning. The operation control key of the suboperation 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.

It is not possible to assign material components or production resources / tools to sub-operations.

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Figure 24: Production Order – Material Components

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.

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Figure 25: Production Order – Production Resources/Tools

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 resource/tool and its relationship to a certain object (material, equipment and so on).

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Figure 26: Production Order – Documents

You can assign any number of documents, maintained in the document management system (DMS), to a production order. The documents are only linked to the production order but not saved with it. Links from documents to a production order can be created manually or automatically.

Documents can constitute illustrations, texts, videos and more besides. Application examples:

Product descriptions

Assembly instructions and drawings Inspection instructions and certificates Safety and health operating procedures Storage and shipping instructions Spare parts list

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Figure 27: Production Order - Execution Steps

Execution steps (XSteps) are used for the variable description of process instructions and messages in the production order. They are the basis on which data can be exchanged with the process control level (downloading control instructions and uploading process messages) and interactive work instructions generated for the machine operator.

Execution steps allow any process instructions (maintained in the XStep repository, in the routing or in the production order) to be assigned to the production order.

Process instructions for work instructions can be outputs, inputs and control functions, such as function calls and process messages.

Application Examples:

Process instructions Molding pressure, pressing temperature, feed rate, …

Process message Creation date, actual time, actual material consumption, actual

processing quantity, processing status of operations, machine condition, …

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As of Release 6.0 and Enhancement Pack 3 of the SAP ECC system, execution steps are available both in the routing and in the production order.

Figure 28: Production Order – Costs

If order-related cost object controlling is used, each individual production order has a cost object (CO object).

The costs incurred for an order can be calculated manually or automatically. You define this by setting up the order-type dependent parameters accordingly in Customizing.

The CO object allows you to display different lists of costs for a production order. From within an order, by choosing → GOTO → COSTS from the menu, you can find lists for the terms

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

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Figure 29: Production Order – Settlement Rules

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 performed 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 cost collector and not in the production order. You can find the settlement rules within the order by choosing

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Exercise 5: Production Order Structure

Exercise Objectives

After completing this exercise, you will be able to:

• Explain the structure (data and contents) of a production order

Business Example

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.

Task 1:

1. Create an order with the following data:

Material R-F1##

Production plant 1000

Order type PP01

Total quantity 1 piece

Finish date Any

Scheduling type Backwards

Method:

ECC → Logistics → Production → Shop Floor Control → Order → Create→ With Material

Task 2:

Display the individual data segments, screens and their data fields in the order: 1. Order header screens

Choose:

→ Goto → Header

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General Assignment Goods receipt Control Dates/Quantities Master data Long Text

Also notice the settlement rule of the order. Choose:

→ Header → Settlement rule

2. Overview of operation sequences Choose:

→ Goto → Overviews → Sequence overview

3. Operation sequence details Choose:

→ Sequence → Details

4. Operation overview Choose:

→ Goto → Overviews → Operations

5. Operation screens (select operation “0010”.) Choose:

→ Operation→ Operation details

Choose the relevant tabs for the screen concerned.

General

Standard values External Processing Interoperation times Standard value calculation Splitting

Overlap

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Dates User fields

Suboperation dates

Quantities/Activities

Confirmed dates

Capacity Requirements Assignments Qualification

Long text

6. Material components - Overview Choose:

Goto → Overviews → Components

7. Material component screens (select component “0010”.) Choose:

Component → Component details

Item “   0010” General data

Long text

8. Production resource/tool overview for operation “0010” Choose:

Go to the operation overview and choose operation 0010. In the menu bar at the bottom of the screen, select the PRT    pushbutton (production resources/tools).

9. PRT screens (select PRT “0010”.) Choose:

Production resources/tools → Details production resources/tools

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Item “   0010” General Quantities Dates

10. Document overview Choose:

Goto → Overviews → Documents

11. Display the document info record (choose the first document). Choose:

Document → Display document info record

Choose the relevant tabs for the screen concerned. Document data Additional data Descriptions Object links Originals

12. Display the original document (display both originals from the document overview for the order).

Choose:

Document → Display original document

13. Costs

Itemization

Analysis (cost types) Cost component split

Choose:

Goto → Costs → Analysis → Itemization

→ Cost component structure

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Task 3:

1. Save your order. Order no.: _________________ Choose:

Order → Save

Task 4:

1. Now change the order by inserting operation 25. Choose:

ECC → Logistics → Production → Shop Floor Control → Order → Change

Then: Goto → Overview → Operations Select operation 0030.

Choose:

→ Edit → Insert → Operation

Use the following data to enter the operation:

Work center no. R-V## Operation control key PP01

Setup time 10 min.

Machine time 10 pieces per 30 min.

Labor time 10 pieces per 60 min.

Task 5:

1. Add any quantity you wish of the material component R-T1## to operation “0030”.

Hint: For this, use item category “L”. Choose:

Go to the operation overview and choose operation 0030.

In the menu bar at the bottom of the screen, select the Components pushbutton.

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Task 6:

1. Assign operation “0050” Install control electronics to material component R-B4## control electronics.

Choose:

Go to the component overview for the order and choose the material component.

In the menu bar at the bottom of the screen, select the Reassign pushbutton.

Use the operation list to select the operation (select by double-clicking in the chose operation).

Task 7:

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Solution 5: Production Order Structure

Task 1:

Material R-F1##

Order type PP01

Total quantity 1 piece

Finish date Any

Method:

a) No answers are required for this exercise.

Task 2:

Display the individual data segments, screens and their data fields in the order: 1. Order header screens

Choose:

→ Goto → Header

Choose the appropriate tab for the screen.

General Assignment Goods receipt Control Dates/Quantities Master data Long Text

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Choose:

→ Header → Settlement rule

a) No answers are required for this exercise. 2. Overview of operation sequences

Choose:

→ Goto → Overviews → Sequence overview

a) No answers are required for this exercise. 3. Operation sequence details

Choose:

→ Sequence → Details

a) No answers are required for this exercise. 4. Operation overview

Choose:

→ Goto → Overviews → Operations

a) No answers are required for this exercise. 5. Operation screens (select operation “0010”.)

Choose:

→ Operation→ Operation details

General

Standard values External Processing Interoperation times Standard value calculation Splitting Overlap Dates User fields Suboperation dates Quantities/Activities

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Confirmed dates

Capacity Requirements Assignments Qualification

Long text

a) No answers are required for this exercise. 6. Material components - Overview

Choose:

Goto → Overviews → Components

7. Material component screens (select component “0010”.) Choose:

Component → Component details

Item “   0010” General data

Long text

8. Production resource/tool overview for operation “0010” Choose:

Go to the operation overview and choose operation 0010. In the menu bar at the bottom of the screen, select the PRT    pushbutton (production resources/tools).

a) No answers are required for this exercise. 9. PRT screens (select PRT “0010”.)

Choose:

Production resources/tools → Details production resources/tools

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Item “   0010” General Quantities Dates

a) No answers are required for this exercise. 10. Document overview

Choose:

Goto → Overviews → Documents

11. Display the document info record (choose the first document). Choose:

Document → Display document info record

Choose the relevant tabs for the screen concerned. Document data Additional data Descriptions Object links Originals

12. Display the original document (display both originals from the document overview for the order).

Choose:

Document → Display original document

a) No answers are required for this exercise. 13. Costs

Itemization

Analysis (cost types) Cost component split

Choose:

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Goto → Costs → Analysis → Itemization

→ Cost component structure

Task 3:

1. Save your order. Order no.: _________________ Choose:

Order → Save

Task 4:

1. Now change the order by inserting operation 25. Choose:

ECC → Logistics → Production → Shop Floor Control → Order → Change

Then: Goto → Overview → Operations Select operation 0030.

Choose:

→ Edit → Insert → Operation

Use the following data to enter the operation:

Work center no. R-V## Operation control key PP01

Setup time 10 min.

Machine time 10 pieces per 30 min.

Labor time 10 pieces per 60 min.

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Task 5:

1. Add any quantity you wish of the material component R-T1## to operation “0030”.

Hint: For this, use item category “L”. Choose:

Go to the operation overview and choose operation 0030.

In the menu bar at the bottom of the screen, select the Components pushbutton.

Task 6:

1. Assign operation “0050” Install control electronics to material component R-B4## control electronics.

Choose:

Go to the component overview for the order and choose the material component.

In the menu bar at the bottom of the screen, select the Reassign pushbutton.

Use the operation list to select the operation (select by double-clicking in the chose operation).

Task 7:

1. Save the order and check your changes.

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Exercise 6: Order Creation Without Master

Data

Exercise Objectives

After completing this exercise, you will be able to:

• Manage the dialog for creating and changing a production order

Business Example

As production manager, production scheduler or supervisor, from time to time you must create production orders for which there is no master data (routing, BOM). This is the case in particular if production has to carry out unplanned work, special requests and other tasks. In this exercise, you will become familiar with the dialog for creating or changing a production order.

Task:

Material T-MAN

Order type PP01

Total quantity 10 pieces

Finish date Any

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Hint: A dialog box appears: Routing Selection T-MAN. React to the system message: No routing found with:

→ Generate operation

Hint: A dialog box appears: BOM Selection.

React to the system message: Do you want to explode a BOM for a different material? with

→ No

Hint: A dialog box appears: Adopt reference text? React to the system messages as follows:

→ Yes

2. Display the operation overview. Operation 0010 has already been created automatically.

Choose: → Goto → Overviews → Operations

3. Create an operation 0020. Use the following data to enter the operation:

Work center no. R-V##

Operation control key PP01

Setup time 10 mins

Machine time 10 pieces per 30 mins

Personnel time 10 pieces per 60 mins

4. Save your order. Order no.: _________________ Choose: Order → Save

5. Now change the order. Use the following data to enter an additional operation 0030: