Sap Pp User Manual

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SAP Implementation

Project - Talema

USER MANUAL

Production Planning

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Production Planning User Manual Version 1.0 DOCUMENT CONTROL SHEET

GENERAL INFORMATION

Project name Document name Document location

Talema Production Planning

DOCUMENT INFORMATION

Version Filename Date Autho

r Reviewed by Changes from previous version V 1.0 EUT -PP 19-03-2008 REFERENCE DOCUMENTS

Document Version R Reference

DOCUMENT Submission Prepared by Received by Anand Srinivasan (Wipro InfoTech Ltd.) Page 2 of 152

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Production Planning User Manual Version 1.0

USER MANUAL TABLE OF CONTENTS

___________________________________________________________ 1

1 MASTER DATA IN PP MODULE

...

4

2 BILL OF MATERIAL (BOM)

...

14

3 WORK CENTER

...

17

4 ROUTING

...

24

...

27

5 PLANNED INDEPENDENT REQUIREMENTS

...

27

6 MRP

...

31

7 MRP LIST

...

35

8 STOCK/ REQUIREMENTS LIST

...

36

9 PRODUCTION ORDER EXECUTION

...

58

10 PRODUCTION ORDER CHANGE:

...

74

11 CAPACITY PLANNING

...

84

12 CAPACITY OVERLOAD:

...

90

13 CAPACITY LEVELING- WORK CENTER VIEW( TABULAR):

...

92

14 CAPACITY LEVELING (GRAPHICAL)

...

105

15 CAPACITY LEVELING (ORDERS)

...

109

16 GOODS ISSUE

...

117

17 GOODS ISSUE (REVERSAL):

...

123

18 PRODUCTION ORDER CONFIRMATION:

...

125

19 CANCELING PRODUCTION ORDER CONFIRMATION:

...

128

20 GOODS RECEIPT FOR AN ORDER:

...

132

21 STOCK OVERVIEW

...

141

22 PRODUCTION ORDER INFORMATION SYSTEM:

...

143

23 COLLECTIVE CONVERSION OF PLANNED ORDERS:

...

146

24 REWORK ORDERS:

...

148

24 REWORK ORDERS: ………..

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Production Planning User Manual Version 1.0

SAP R/3 Brief Introduction:

In SAP R3, modular data is classified as Master data and Transaction data.

Master data is defined as the main details of individual modules’ objects. Typically

in the PP module, main objects are Materials, Bills of Material, Work Centers, Routings. It contains details about characteristics about those objects like material type, planning requirements, to produce a certain finished good, what proportion of semi-finished and raw materials are needed, , work instructions to carry out tasks,. Whilst Transaction data captures the day-to-day activities and include production orders, issuing raw materials/ semi-finished materials those orders, receiving finished goods from the orders. When a transaction is initiated, master data is transferred into it through logical links.

1 MASTER DATA IN PP MODULE

Material Master

SAP menu Logistics ->Production -> Master Data -> Material Master ->Material -> Create (General) -> Immediately

Transaction code MM01

SAP menu Logistics ->Production -> Master Data -> Material Master ->Material -> Change -> Immediately

Transaction code MM02

SAP menu Logistics ->Production -> Master Data -> Material Master ->Material -> Display -> Immediately

Transaction code MM03

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Enter Industry sector, choose Mechanical industry from the dropdown; choose material type from the dropdown. In this case it is semi finished Product. Press Enter. You will be prompted to choose the required material views. Production Planning requires the following views viz. Classification; MRP1, MRP2, MRP3, MRP4, Work Scheduling. Highlight these views and press tick button.

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Enter TSMU or choose TSMU (i.e. Talema mother unit Plant) from the dropdown for Plant. Choose the Storage Location WPMU from the dropdown. This is where material is stored. Press Tick.

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You will enter into MRP view no.1 screen.. Choose PD from the dropdown list in the MRP Type field. PD is the simplest form of MRP type. It is the most flexible MRP type. PD instructs the system to fine tune the planning... Choose appropriate MRP controller from the dropdown menu. This is the person who does the planning run. Choose the Lot Size EX from the dropdown. EX defines that production lot quantity will vary for every production.

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Press the MRP2 tab. Here, Choose E from the dropdown. This states that this material is produced in house. Suppose, if a material needs to be procured externally sometimes, then choose X.

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Press MRP3 tab. Enter Strategy group as 10. This indicates that the strategy adopted is Strategy No. 10, which is plain vanilla Make to Stock production. Enter

02 in the Availability check field. That is we will use checking group 02 for

availability check.

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Press MRP4 Tab. This view is the most important view of all. It stores essential details of a material. For materials in Talema with alternate BOMs, for Selection

method field choose 3 from the dropdown menu. This instructs the system how an

Alternate BOM should be selected for a production order. 3 states that Alternate BOM is selected via a Production version. A Production Version is another PP master data, which identifies various BOM/ Routing combinations. For Individual/ Coll. Field, for materials which has options of components or assemblies, choose 1 from the dropdown. 1 states that the requirements generated are individually. For other materials leave this field blank.

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In the same screen, press the Prod Versions button, there will be a pop-up displaying the list of Production versions of that material. In this case it is S20461. Click on the Continue button or press Enter.

[ Please note: Creating a Production version is dealt latter in this manual.]

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Press the Work Scheduling tab. Enter the appropriate person in the Production

Scheduler field. For 1008, 008 is the Production Scheduler. In the Prod.Sched.Profile field, choose 000001 from the dropdown for all the materials.

This profile instructs the system how production is executed in shop floor. Example as to when the production order should be released, etc.

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Production Planning User Manual Version 1.0 2 BILL OF MATERIAL (BOM)

SAP menu Logistics ->Production -> Master Data -> Bills of Material ->Bill of Material-> Material BOM -> Create

Transaction code CS01

SAP menu Logistics ->Production -> Master Data -> Bills of Material ->Bill of Material-> Material BOM -> Change

Transaction code CS02

SAP menu Logistics ->Production -> Master Data -> Bills of Material ->Bill of Material-> Material BOM -> Display

Transaction code CS03

BOM is a master data which contains what proportions of input materials are required to produce a std. quantity of output.

Choose the Material and Plant from the dropdown list.

Choose BOM Usage 1 from the dropdown. ( Usage 1 is Production)

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Production Planning User Manual Version 1.0 Enter the Alternate BOM No. Alternate BOMs are alternate combinations of input materials. 1st Alternate will have 1. 2nd Alternate will have 2 and so on.

Press the Cap button at the top. It symbolizes Header data.

Here, enter, the Base quantity of the Header material as 1. Base quantity is used as a base for requirements calculation.

Under Alt Text, you can give some text about this alternate say, some keywords for you to identify later.

Press the Item button at the top.

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Here in the item screen:

Enter the required input materials under the column field Component. Choose L from the dropdown for all materials.

L means Stock items, where you can stock these materials and otherwise it is N, which is Non-Stock item.

Enter the required quantities of them under column field Quantity.

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Production Planning User Manual Version 1.0 3 WORK CENTER

Work Center is a place, where the conversion of input materials to output takes place. In ITL, we will using 2 types of work center category viz. (1) Machine 0001; (2) Labour 0003

SAP menu Logistics ->Production -> Master Data -> Work Centers ->Work Center -> Create

Transaction code CR01

SAP menu Logistics ->Production->Master Data -> Work Centers ->Work Center -> Change

Transaction code CR02

SAP menu Logistics->Production->Master Data -> Work Centers ->Work Center -> Display

Transaction code CR03

Choose the Plant where the work center will be located; Enter the Work Center name.Choose the appropriate Work center cat. From the dropdown. In this case, it is 0001.Press the tick button at the top

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For Usage field, choose 009 from the dropdown list. Here, we are instructing the system to allow all kinds of task list types for this work center.

For Standard value key, choose SAP for Normal Production from the dropdown menu. Then press tick at the top left of the screen.

For Set up, choose No checking from list

For Machine, choose should be entered from list For Labour, choose should be entered from list

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Press the Default values tab. Enter Control Key PP01,

For Standard text key, choose the desired one from the dropdown list. For Printer, choose the desired one from the dropdown list.

For Set up, enter MIN in the Std. Value unit field from list For Machine, enter MIN in the Std. Value unit field from list For Labour, enter MIN in the Std. Value unit field from list

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Press Capacities tab.

Enter prime Capacity category as 001. (For assembly Work centers select 002). Enter SAP006 in Processing formula field. (For assembly Work centers select SAP0007).

If a secondary capacity exists say, labour enter secondary Capacity category as

002.

Press tick button at the top left.

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You will be presented with the Capacity header screen. Here, you will enter wide details about the capacity(s).

Enter the name of the capacity as BED LENGTH1100/CENTER HEIGHT. 250; Choose

Capacity planner grp. as 1;.

Choose Factory calendar ID as I8; Active version as 1; Base unit of meas. as HR

Capacity availability times: Enter Start as 08:30:00 till Finish as 00:00:00 the next day.

Length of Breaks as 03:00:00; Capacity utilization as 100; No. of indiv. cap units as 3;

In Capacity field, enter HR

Indicate for all work centers in the following checkboxes : Relevant to finite

scheduling;

Can be used by several operations; Long-term planning.;

Press the tick button at the top left of the screen.

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Press the Scheduling tab. Here, we indicate that which capacity is used to schedule this work center. Always use Capacity category 001 to schedule. Processing

formula is SAP002. (For Capacity Category 002 select SAP003.

Work dimension is TIME & Work unit is HR. Press the tick button at the top left.

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Press the Costing tab.

In the Cost Center choose the appropriate cost center from the dropdown list. By doing so, we are assigning this work center to the cost center where all the activity costs will be booked.

For Labour in the Activity Type, choose 1030; in the Activity Unit, enter MIN; in the

Formula field, choose SAP003

Note: Please do not forget to tick the checkbox Ref. checkbox. for all the relevant

activity types. By doing so we are indicating that these parameters are transferred to Routings where this work center is used. Press tick button and then press the

save button at the top.

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Production Planning User Manual Version 1.0

4 ROUTING

Routing is a task list where work instructions regarding how material wise production conversion takes place in the designated work center are stored.

SAP menu Logistics ->Production -> Master Data ->Routings ->Routings-> Standard Routings->Create

Transaction code CA01

SAP menu Logistics ->Production -> Master Data ->Routings ->Routings-> Standard Routings->Change

Transaction code CA02

SAP menu Logistics ->Production -> Master Data ->Routings ->Routings-> Standard Routings->Display

Transaction code CA03

Enter Material as S20461.

Enter Plant as TSMU, which is our Talema MU Press the tick button at the top left end.

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Enter the desired task list description by which one can recognize at the time transactions eg. Production Orders. Here, enter 1008.

Enter Usage always as 1; Status is always 4

In this case, From Lot Size is 1 and To lot size is 99,999,999 and their unit is EA. Press the tick button. Press the Operations button.

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You will see, Operation step nos. 0010 to 0080. Against each step, choose the appropriate Work Center, where that operation takes place. In Control key column, choose PP01 or PP06 for operations, Enter the individual Operation steps in the

Description column viz Winding1:75/1.02 by RW2/15, etc; Enter 1 as Base quantity(

Base quantity is the std. output quantity.); Enter the values for all the costing activities for each operation viz. Dur M/C HR, Dur Lab HR.

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Production Planning User Manual Version 1.0

5 PLANNED INDEPENDENT REQUIREMENTS

So far we have seen the master data. Now we shall see the transaction data.

Planned Independent Requirements (PIRs) are prime input for Production Planning. Since Make to Stock strategy is adopted at component / assembly across whole of ITL, PIRs are taken as requirements that are likely to be realized. In other words, they epitomize the function of their 3 month plan to facilitate raw materials’ procurement that has a lead time varying from 20 to 50 days and at the same time give flexibility to change the production plan at any time, keeping in line with changing sales situation.

SAP menu Logistics-> Production-> Production Planning-> Demand Management ->Planned Independent Requirements-> Create

Transaction code MD61

SAP menu Logistics-> Production-> Production Planning-> Demand Management ->Planned Independent Requirements-> Change

Transaction code MD62

SAP menu Logistics-> Production-> Production Planning-> Demand Management ->Planned Independent Requirements-> Display

Transaction code MD63

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Enter the desired Req. plan number, say, Anand01, and his Plant as TSMU Under Planning Horizon, say, enter From as 19.03.2008 and To as 30.05.2008

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Here, enter all the Materials in that Plant TSMU. Enter the Plant as TSMU for all the Materials.

For each Material, enter the monthly requirements, say for the next 3 months.

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Press the Sched. Lines tab. Here, for materials you need a weekly requirement, monthly requirement is split by choosing W – Week format from the dropdown.

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Press the Table tab again. Now, the weekly split is visible.

6

MRP

MRP Run or Planning Run is an engine which converts the requirements elements

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Production Planning User Manual Version 1.0 (Issues) into planned supply elements (Receipts) and Balances the Demand/ Supply gap. Issues & Receipts are called MRP Elements. Issues include PIRs, Dependent Requirements, Order Reservations, Sales Orders, Issuing Stock Transfer Orders, etc. Receipts include Planned (Production) Orders, Purchase Requisitions, Purchase Orders, Open Production Orders, Receiving Stock Transfer Order, Schedule lines, etc. Having said that, when we run MRP, Planned orders are generated to offset the PIRs of Top level materials and Dependent Requirements of lower level products. These Planned Orders can be converted to actual Production Orders later and are executed then. Purchase Requisitions are generated for Raw materials, which are converted to Purchase Orders to fulfill these requirements.

Total Planning : (Plant wise planning)

SAP menu Logistics ->Production -> MRP ->Planning->Total Planning ->Online

Transaction code MD01

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Total Planning is used planning for all the materials in a plant in 1 transaction.

Enter Plant, as TSMU

Choose Processing Key as NETCH(Net Change in Total Horizon)

Create purchase req. as 2; Schedule lines as 2; Create MRP list as 1 Planning Mode: 3; Scheduling: 2.

Keep pressing the tick at the top left end multiple times and accept all the warning messages.

Now, press this message box tick to complete the run.

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The above is the result of our planning run. It shows the number of materials planned.

It also shows the no. of planned orders and purchase requisitions generated, etc.

Single- item multi level planning :

SAP menu Logistics ->Production -> MRP ->Planning->Single item

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multi level Transaction code MD02

Here, individual material is planned individually. Enter Material, say, S20461

Enter Plant, TSMU

Processing key, NETCH ( Net Change for total horizon) Create purchase req. 2

Delivery schedules 2 Create MRP list 1 Planning mode 3

Scheduling 2 Press tick twice

This our MRP results screen. 7 MRP LIST

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Production Planning User Manual Version 1.0 MRP list is a static report displaying the detailed results of the planning run material wise. It displays the time of the MRP Run at the top.

SAP menu Logistics ->Production -> MRP ->Evaluation -> MRP list Transaction code MD05

This displays the Receipt elements against the Issue elements.

8 STOCK/ REQUIREMENTS LIST

Stock/ Requirements list unlike MRP list is a dynamic report giving you up to date information about new requirements of that material like PIRs, Issue Stock Transfer order, Sales orders etc. ( Please note that here Sales orders wont influence

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Production Planning User Manual Version 1.0 anything since we are making to stock) and new receipt elements like up to date Stock level, newly converted Production order, etc)..

SAP menu SAP R/3 Menu Logistics ->Production -> MRP ->Planning->Evaluation-> Stock/ Requirements list

Transaction code MD04

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The above is Stock/ Requirements list of a semi-finished level material. Hence, one finds Dependent requirements and the MRP element which it refers to i.e. all the 4000X level materials.

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Here, we take one of the planned orders which are generated against the dependent reqts. Say, Planned order no. 0000000006 by double clicking the lens. You will get this pop-up. Click the pencil image.

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You can change Order quantity to desired value, .

( Note: Alternately, this screen can also be reached by the transaction code MD12 and entering planned order no. 6)

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You can also change the planned order dates and schedule/ reschedule it.

You may want to test the possibility of a new desired date. Enter a new basic finish

date, say 21.02.2008 in place of the old basic finish date. Press Schedule planned order at the top. The system does Backward Scheduling from that date.

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System has generated new basic dates viz. 02.04.2008 to 02.04.2008. The above screen displays the routing object of this material to do backward scheduling

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You can also do Capacity Leveling to level the uneven load on the BP, L1( our work center in our example).

On the menu tree at the top of screen, click Goto and under that click Capacity

Leveling.

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You will get this pop-up input box. Here, click Detailed plnng radio button and Days radio button.

Enter Period of evaluation as From 19.03.2008 and to 30.04.2008 . Press the tick in the input box.

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This is Detailed Planning screen. It displays the available capacity for that month day wise( equipment hrs.) and Total requirements( equipment hrs) every day.

Press the Pegged Requirement button at the top of the screen.

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In pegged requirements, which particular planned order has consumed this capacity can be traced to.

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As we come down, we find that apparently there is capacity overload as indicated by overload sign on the left.

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Now we shall look at detail overload view by pressing the Overload button at the top left corner of the screen.

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Here one can see that the max. load for this WC is 341.5%. Therefore a caution for us.

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By clicking the + sign on the left side of the capacity, we get elaborate details of the load. The WC Ruff is shown overloaded for a period of time

Now, press the Overview button at the bottom right of the screen.

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The capacity for all days of the month is displayed, along with overload.

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Now, concurrently, pay a visit at the Stock/ Requirements list of T-Trans1(Torroidal transformer 18737-P1S01).

Like above we correct and scheduled all the planned which fell on same day

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After correcting and editing the planned orders, we can find in that the capacity is not exceeding beyond 100%. i.e. capacity is under check!

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We can see that the planned order 0000000048 now has an asterix sign in suffix. This means that this planned order is firmed. That is this planned order will be retained and not be replaced by any other planned order when the next MRP is run.

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You can see that this planned order is firmed as the checkbox Plnd order is ticked.

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The Capacity leveling we saw before can also be accessed directly in Stock/ Requirements list( MD04). In the menu tree at the top, click goto and under that, click Capacity Situation.

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Production Planning User Manual Version 1.0 9 PRODUCTION ORDER EXECUTION

We have already created the planned production orders. Now we need to convert these planned orders into actual production orders and execute. You can create production orders through one of 3 ways.

(i) Directly from Stock/ Requirements list.

(ii) Entering the planned order no. eg. 0000000048 in the following transaction. SAP menu Logistics ->Production -> Production Control

->Order->Create ->From Planned Order Transaction code CO40

OR

(iii) Creating a Production order without referring any planned orders.

SAP menu Logistics ->Production -> Production Control ->Order->Create ->With material

Transaction code CO01

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Now, let us consider the first 2 methods. From Stock/ Requirements list, by double clicking the desired planned order, you will get this pop-up. Press ->Prod. ord button to convert this planned order to production order.

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You will enter into this screen, which is our CO40 transaction.

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You will get the pop up saying that Capacity available at all work centers. Press the tick in this screen.

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Now press the button Materials at the top of the screen. You will get the message-

All checked materials in order are available. Otherwise you will get the pop-up Missing parts overview/ Missing parts list. These lists will give the parts which is

deficit quantity.

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You can also view if there is any material shortage. From the menu tree goto ->

Missing parts->Missing parts overview.

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You can view the std BOM quantities required to produce 48 Nos of T-trans1 by pressing the Component overview button (BOM sign) at the top.

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The above screen shows the std. reqd. quantities of the input materials. You can also assign respective storage locations of those materials if you want to.

Press the Operations button at the top( next to cap sign).

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This is Operations overview screen, which gives the schedule of this production order.

Now, double click on one of the operation nos., say, operation no. 0050. to enter into the operation detail screen.

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This is operation details screen. In this, press the StandardVals tab at the centre. Here you can see the std. costing activities for that operation. If you have not entered these std. value at the routing level, you can enter this here at any time before this order is released.

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Now, press the Cost Order button (calculator sign) at the top. Press back button twice at the top to come back to main screen.

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Here, press from the menu tree: Goto->Costs-> Itemization

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Here, what you see is the planned costs of this production order.

Now press save button at the top to save the order.

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This production is saved as this number 1000017.

10 PRODUCTION ORDER CHANGE:

SAP menu Logistics ->Production -> Production Control

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>Change Transaction code CO02

Enter the production order no. in the field Order, 1000017.

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Now we need to dispatch the work center to this order. So, we can use this workcenters for the order.

Highlight all operations; press the menu tree at the top Operations-> Dispatch to dispatch this order to the work center.

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Now, you can see the column SysStatus, all the operations are having DSPT status. That is, they are being dispatched.

Now, click the back button at the top to return to the header screen.

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At the top of the screen menu tree, click Goto->Graphic-> Operations.

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This is the operation graphic of the production of this material.

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From the menu tree at the top, press Goto-> Graphic->Gantt chart

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This shows the graphic of operations scheduling using backward scheduling.

[Please note: Now, we will leave this production order 1000017 temporarily suspended for now. We shall see how Capacity is managed and scheduled to the exact minute of the day. If this step is to be done, it has to be prior to release of the production order.]

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11

CAPACITY PLANNING

Capacity Load:

SAP menu Logistics ->Production -> Capacity Planning -> Evaluation->Work Center View->Load

Transaction code CM01

In this transaction, one can see the weekly capacity load of a work center. Enter the Work center code, TJ01

Enter Plant, TSMU

Press the Standard overview button at the top.

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The above screen shows, the capacity requirements( equipment hours); available equipment hours; capacity load( % of total capacity); Remaining available equipment hours.

You can pick the required week by ticking the checkbox on the left side of that row. After, selecting, press the Cap. details/ period.

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In this screen, you will see the detailed display of individual load elements and the source of these load(s) in the column PeggedRqmt. Sources are planned orders & production orders.

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Now in the same transaction, after entering Work center & Plant, press the button

Variable overview.

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In this screen, you can distinguish the group into Wk. orders (Production orders); Pl. orders( Planned orders) and sum of the two, etc.

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Production Planning User Manual Version 1.0 12 CAPACITY OVERLOAD:

SAP menu Logistics ->Production->Capacity Planning->Evaluation-> Work Center view->Overload

Transaction code CM05

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You can see in this screen that the system displays the weeks in which there is capacity overload.

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13

CAPACITY LEVELING- WORK CENTER VIEW( TABULAR):

SAP menu Logistics ->Production->Capacity Planning->Leveling-> Work Center view->Planning Table- (Tabular)

Transaction code CM22

Enter the Work Center, TJ01 Enter the Plant, TSMU

Press the filter (funnel) button at the top.

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Choose the Order Cat. as 1 (which means only Production Orders will be displayed) You can also further filter your criteria with Order, 1000017

You press the execute (clock) button.

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In the top section, tick the checkbox at the left side of the row of the Work center capacity 001, which is Equipment Hrs.

Now, under the Requirements section beneath, tick the checkboxes at the left side for all the rows relevant for dispatching. You can see, each operation, operations of

order no. 1000017. We are dispatching the capacities viz. Equipment Hrs.(001).

Press the Dispatch manually button at the top.

[Note: Please recollect whilst creating the work center we had indicated that although these 2 capacities are used for dispatching, only Equipment Hrs. is used for Scheduling the work center in the time dimension.]

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You will get this pop-up. In this, tick checkbox at the left side of Equipment Hrs. row.

Enter the new desired scheduled production dates/ time viz. Start 20.03.2008 at

12:45 hrs. and Finish 20.03.2008 by 24:00 hrs.

Press the Dispatch button at the bottom.

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Now, we check the scheduling results by clicking Extras-> Log-> Planning

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The above is the Planning message box. It says that there are 3 Information

messages; 1 warning messages and no error or termination messages. Former 2

are acceptable but not the latter two.

Click on the right side of Warning messages.

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This screen shows all the 3 messages.

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14 CAPACITY LEVELING (GRAPHICAL)

SAP menu Logistics ->Production->Capacity Planning->Leveling-> Work Center view->Planning Table- (Graphical)

Transaction code CM21

It is ditto same as that of Tabular form. Enter Work Center- TJ01

Enter Plant- TSMU

Press the filter ( funnel) button.

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Here filter the desired criteria you want. Choose Order Cat.-1 from the dropdown. Enter Order- 1000017

Press execute (clock) button at the top.

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The order “slabs” are in red. Choose each operation and drag it along the desired date in the X axis time graph by a green color vertical line.

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Now we have scheduled it to new desired dates, operation by operation.

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The above is the planning log message what we get.

15 CAPACITY LEVELING (ORDERS)

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Production Planning User Manual Version 1.0 Here, we can level& schedule

SAP menu Logistics->Production->Capacity Planning->Leveling->Order view->Planning Table- Order View (Tabular)

Transaction code CM23

Here, enter Order nos. 1000000 to 1000017

Press the filter button at the top, if you want to refine your criteria.

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Enter the filtering data, if any. Press the execute (clock) button.

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Here, we are selecting the rows of order no. 1000005. Press the Dispatch Manually button at the top.

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You will get this pop-up. Choose the work center where you want to dispatch and schedule this order in.

Press the Dispatch Manually button at the bottom left of the pop-up.

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…Now we will resume our Order execution 1000017 from where we left.

Remember, we have dispatched & scheduled our order with Start. at 07:00 hrs, on 20.03.2008 & Finish by 11.41 hrs. on 20.03.2008.

Having dispatched this order to new scheduled dates manually, we will release this production order. Please remember after releasing & saving the order, one cannot change the order parameters anymore.

Press the Release (Green colour flag) button at the top left.

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Order has been Released Double click on the Status line.

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You can see that our order now has the Released status. Click the back (arrow) button to go to main header screen.

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Now, the most important step: Press the save button at the top.

16 GOODS ISSUE

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SAP menu Logistics ->Production->Production Control ->Goods Movement->Gods Issue

Transaction code MB1A

Here, one can give goods issue to an order.

Enter Movement type as 261 (Always this is the movement type, which has 261) Enter the Plant as TSMU & Storage location

If you want to print this one, tick the checkbox Print at the bottom left. Click To Order.

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Enter the Order no. 1000017 Click Adopt Details. Enter the input materials in the Material column

Required quantities for each material in the Quantity column. Unit of measure KG in UnE column.

Enter the respective storage location in the column SLoc

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Press the Adopt button.

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Now, press the save button.

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Information “Document 4900000140 posted.

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17

GOODS ISSUE (REVERSAL):

Goods Issue Reversal is canceling the Goods Issue given for that order. Goods Issue can be cancelled for any order any time until the order status becomes CNF, which is Confirmed.

SAP menu Logistics ->Production->Production Control ->Goods Movement->Gods Issue

Transaction code MB1A

All details are same except that the Movement type in this case is 262. Enter.

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Enter the Material codes, reversal quantities( mirror image of the issue quantity), unit of measure, even the same batch no. that was issued before. So, care must be taken whilst doing this one.

Press tick button at top left of screen. In the next screen, press save button to post.

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18

PRODUCTION ORDER CONFIRMATION:

Production Order Confirmation is a transaction which lets the system know that the production order execution has been completed. The resulting actual yield quantity, costing activity actuals like time taken, steam consumed, fuel consumed, electric power used, etc.

SAP menu Logistics ->Production->Production Control ->Confirmation->Enter-> For Operation->Time Ticket Transaction code CO11N

Enter, Order no. 8000016

Choose, Confirm. Type Final Confirmation.

Tick the right side checkbox Clear open reservations.

Click the actual data, the system proposes the actual yield quantity of the order & the actual machine time.

Press the tick button at the top left corner of the screen.

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Similarly confirm the rest of the operations in the production order.

Enter any text you may want to add in the text. For eg. You can give the details regarding the delay in the order completion as shown above.

Press the tick button at the top left side. Press the save button.

Alternately we can confirm the at the production order level

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By confirming at the order level, all the operations are confirmed at once

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You can see that the order 8000017 is now having the status CNF, i.e. CONFIRMED

19 CANCELING PRODUCTION ORDER CONFIRMATION:

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SAP menu Logistics ->Production->Production Control ->Confirmation->Cancel

Transaction code CO13

Enter the Order No. 8000017

Press the tick button at the top left corner of the screen.

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You will get this pop-up. Press the Yes button.

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Press the save button at the top.

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Production Planning User Manual Version 1.0 20 GOODS RECEIPT FOR AN ORDER:

Goods Receipt is the transaction used for receiving the materials.

SAP menu Logistics ->Production->Production Control ->Goods Movement->Goods Receipt

Transaction code MB31

Enter Movement Type, 101 Enter Order No. 8000017 Enter Plant TSMU

Tick the checkbox Print, if you want to. Press the Adopt + Details button at the top.

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[Please note: This step is very important for the order status to get DLV, Delivered. Otherwise status becomes PDLV, Partially Delivered. For CO users to calculate variance & settle a production order, status has to be either DLV or TECO]

Press Adopt button at the top left.

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Press the save button at the top to post the document.

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You will get this screen by double clicking at the bottom of the screen, which says that this Goods Receipt is being posted in the document no. 5000000040.

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Now, we see in the order header screen in the Goods Receipt section. The checkbox Delivery Completed, is being ticked.

Please note that, suppose in case of production orders having co-products with indefinite receipt quantities, we may have to do multiple goods receipt transactions, even if we forget to click del. Comp checkboxes in those transaction, we can click it here. Till this checkbox is ticked, the order wont have DLV status.

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You can see that our order has the status DLV, Delivered.

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Now, we can see the costs analysis by clicking the menu tree Goto-> Costs->

Analysis

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The above screen gives the analysis of actual costs realized from this order. Press the Layout (Cube) sign.

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You can select the required columns from being hidden into display by manipulating the directions.

The desired columns have been added for our display.

21 STOCK OVERVIEW

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Production Planning User Manual Version 1.0 In the Stock overview, one can see the display of available stock at any point in time.

SAP menu Logistics ->Materials Management->Inventory Management->Environment->Stock-> Stock Overview Transaction code MMBE

Enter Material 40000004 Enter Plant TSMU

Press the execute button at the top left corner.

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You can see from the above screen that the qty is in unrestricted use

22 PRODUCTION ORDER INFORMATION SYSTEM:

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SAP menu Logistics ->Production -> Production Control ->Information System-Production Order Information System

Transaction code COOIS

This is prime PP report.

Example, choose Order Headers from the dropdown menu, in List

You can further filter you selection by entering From which Material To which

Material

Or From Production Order No. To Production Order No.

Choose the desired SYSTEM STATUS, eg. If PP person wants to see which all orders that are CREATED. He shall choose CRTD, Orders created.

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The above is the list of created production orders, which is to be dispatched to workcenters.

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Production Planning User Manual Version 1.0 23 COLLECTIVE CONVERSION OF PLANNED ORDERS:

SAP menu Logistics ->Production -> MRP-> Planned Order->Conv. To Prod. Ord.- Collective Conversion

Transaction code CO41

This transaction can be used to convert multiple planned orders into production orders. For example, you can convert all/ some of the planned orders of the any/ some/ all of materials controlled by the MRP Controller. 001 can convert all/ some of the planned orders of the any/ some/ all of the materials at one go. However, some care should be taken in choosing the orders to be converted.

Enter Plant, TSMU

Choose MRP Controller from the list , 001 You can filter the selection criteria with Material

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Highlight and select the Planned Order rows. Press Convert button at the bottom left of screen.

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24

REWORK ORDERS:

Rework order will be differentiated from standard order by order type :PP03

Rework orders can be created manually or automatically using trigger point in an operation

Manually created rework order

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Automatically created rework order will have “gear symbol”

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Rework order screen

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When going to component overview there is no component assigned in the BOM for that rework order

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Component have to be assigned manually

Figure

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References