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(2) Appendix: mySAP Business Suite and Production. Contents: mySAP Business Suite: Solutions, Key Areas, Components Key Areas in the mySAP SCM Solution Roles in Production Components in the Key Area Production Master Data for Production Integration of Production in Planning. SAP AG 2003. © SAP AG. SCM300. Appendix-1.
(3) Value Creation Using the mySAP Business Suite SAP xApps. mySAP Business Suite. mySAP SCM. mySAP SRM. mySAP Financials. mySAP CRM. mySAP HR SAP BI. Corporate Services Operations. SAP NetWeaver. SAP Enterprise Portal. Industry Solutions. SAP Customer Service Network. mySAP PLM. mySAP ERP. SAP R/3 Enterprise. Application Platform (Web AS) People Integration (Portal) Information Integration (BW, MDM) Process Integration (XI) SAP Business One. SAP AG 2003. The mySAP.com Business Suite offers cross-industry and industry-specific solutions. Cross-industry solutions are, for example, mySAP SCM (Supply Chain Management) and mySAP PLM (Product Lifecycle Management). Each solution has different key areas. The mySAP SCM solution, for example, contains the key areas SCM planning and SCM production. Each solution and key area is technically realized using components. The key areas SCM planning and SCM production use the components SAP R/3, SAP APO (Advanced Planning and Optimization) and SAP BW (Business Information Warehouse). The mySAP Business Suite is based on SAP NetWeaver, which is an open, scalable infrastructure that allows the integration of heterogeneous environments (SAP and non-SAP components) The SAP NetWeaver comprises the SAP Web Application Server, the portal infrastructure, the exchange infrastructure and information integration. The SAP Web Application Server supports native Internet technology (HTTP, XML), JAVA and ABAP. In addition to the solutions themselves, SAP offers corresponding services: The SAP Customer Service Network allows customers to maximize the return of investment using the mySAP Business Suite. The SAP Customer Service Network comprises: Business Solutions Consulting (Business Solution Design: concepts of business solutions, project management, Continuous Business Improvement); Solutions Operations Services (technical implementation and continuous optimization); training; support (24x7 support, EarlyWatch, GoingLive).. © SAP AG. SCM300. Appendix-2.
(4) Solutions (1). Cross-Industry Solutions. Industry Solutions. mySAP Enterprise Portals. mySAP Aerospace & Defense. mySAP Insurance. mySAP Customer Relationship Management. mySAP Automotive. mySAP Media. mySAP Banking. mySAP Mill Products. mySAP Supply Chain Management. mySAP Chemicals. mySAP Mining. mySAP Exchanges. mySAP Consumer Products. mySAP Oil & Gas. mySAP Supplier Relationship Mgmt (SRM). mySAP Engineering & Construction. mySAP Pharmaceuticals. mySAP Financial Service Provider. mySAP Public Sector. mySAP Healthcare. mySAP Retail. mySAP High Tech. mySAP Service Providers. mySAP Higher Education & Research. mySAP Telecommunications. mySAP Services. mySAP Hosted Solutions. mySAP Business Intelligence mySAP Product Lifecycle Mgmt mySAP Human Resources mySAP Financials mySAP Mobile Business. mySAP Utilities. Infrastructure und Services mySAP Technology. SAP AG 2003. © SAP AG. SCM300. Appendix-3.
(5) Solutions (2) Industry Solutions. mySAP Public Sector. mySAP Higher Ed. & Research. mySAP Healthcare. mySAP Insurance. mySAP Financial S. Provider. mySAP Banking. mySAP Utilities. mySAP Telecommunications. mySAP Service Providers. Service Financial Public Industries Services Services. mySAP Media. mySAP Retail. mySAP Mining. mySAP Oil & Gas. mySAP Pharmaceuticals. mySAP Mill Products. mySAP CP. Consumer Industries. Process Industries. mySAP Chemicals. mySAP High Tech. mySAP E&C. mySAP Automotive. Cross-Industry Solutions. Discrete Industries mySAP Aerospace & Defense. Financial Services. mySAP Enterprise Portals mySAP CRM mySAP SCM mySAP BI mySAP Exchanges mySAP SRM. Best-of-Breed Solutions for Industries. mySAP PLM mySAP HR mySAP Financials mySAP Mobile Business SAP AG 2003. © SAP AG. SCM300. Appendix-4.
(6) The mySAP SCM (Supply Chain Management) Solution. Partner. Supply Chain Collaboration. Vendor. Planning. Strategy Supply Chain Design. Supply Source External Procurement. Sales and Delivery Planning. Production Manufacturing. Delivery Order Fulfillment. Supply Chain Collaboration. Supply Chain Performance Management. Customer. Partner. Supply Chain Event Management SAP AG 2003. mySAP Supply Chain Management (SCM) is a complete solution that allows a company to efficiently plan, create and control products or services within complex logistics networks. This solution 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. Especially the processing of cross-company processes or collaborative planning and procurement processes, which also allow for a connection to an open market place, is a main feature of this solution.. © SAP AG. SCM300. Appendix-5.
(7) Key Areas in the mySAP SCM Solution. mySAP SCM SC Technology. Sales Processes and Logistics Execution. SC Networking External Procurement. SC Coordination. SC Planning Manufacturing Solution. SC Execution. Key area SAP AG 2003. Supply Chain Technology: Open technological framework; uses internet standards (HTML, XML, WAP) Flexible optimization functions for optimally coordinated logistics chains Superior logistics performance: efficient logistics planning and scheduling using the liveCache Supply Chain Networking: Private marketplace: company-wide information exchange, planning, coordination Company portal: provides user-specific information via the web browser Mobile Supply Chain Management: mobile data entry, allows for seamless information flow Supply Chain Coordination: Supply Chain Event Management: monitors events and processes in the logistics network Supply Chain Performance Management: determines performance figures for process optimization Supply Chain Planning Supply Chain Design: design and optimization of the supply chain infrastructure Company-wide sales and requirements planning Supply Chain Execution Production: supports discrete production (order-oriented or period-oriented) and process manufacturing from planning to realization, creates feasible schedules taking into account the availability of material, capacity and production resource/tools External procurement: covers the whole procurement process from the purchase requisition via the source of supply determination, to the purchase order, goods receipt, invoice verification and inventory management; supports internet-based direct procurement; uses e-marketplaces, catalogs, rules-based procurement strategies for automated procurement Sales Processes and Logistics Execution: manages sales orders with offer creation, delivery date determination, global availability check, picking, invoice documenting; transportation management with transportation planning and vehicle scheduling; delivery tracing © SAP AG. SCM300. Appendix-6.
(8) Roles in Production. Production planner plant manager, MRP controller Production scheduler. Demand planning. Detailed scheduling. Plant reqmts. Industrial engineer. Production worker Production scheduler. Work scheduling. Production. Production worker Production scheduler (foreman). Docu.& analysis. Plant manager, quality manager. Design engineer. SAP AG 2003. With the introduction of the mySAP Business Suite, computer-supported workplaces were created throughout the whole process chain in production. The roles shown on this slide are just a few of the roles required to manage shop floor control. In addition, there are single roles for different activities (tasks), authorizations, and responsibilities which correspond to actual daily work.. © SAP AG. SCM300. Appendix-7.
(9) The mySAP Enterprise Portals Solutions R/2 R/2 3rd 3rd party party. Other Other ERP ERP Systems Systems. not SAP. Tim Brown Production scheduler. 3.1H. SAP Components. R/3 R/3. mySAP mySAP Enterprise Enterprise Portals Portals. Web Browser Access. SEM SEM. BW BW. single single point-of-access point-of-access Integration Integration Role-based Role-based Personalized Personalized. ( ... ) KW KW. APO APO CRM CRM. Syst. em l Inside imita tion. Partner mySAP mySAP Partner Marketplace Marketplace SAP Internet Services. other Internet Services. Outside. SAP SAP. SAP AG 2003. The cross-industry solution mySAP EP (Enterprise Portals) is an open, role-related enterprise portal, which allows a user to have integrated and personalized access to information, applications, and services from internal and external sources via a web browser. mySAP EP is the starting point for an employee to his or her daily work. It makes information and applications available per mouse-click over an interface that is easy to understand, adjust and use. The following characterizes mySAP EP: Single point-of-access: A web browser allows for central access to different applications, contents and services. - Access is possible everywhere and anytime. - Convenient integration of SAP and non-SAP components and applications from intranet and internet services. - Openness and flexibility Personalized and role-based, individually adjustable user interface The description above describes the mySAP EP application using a production scheduler as an example. Based on his or her daily tasks, an employee is assigned a role with special authorizations and system access. A production scheduler is given access to selected functions from the SAP components R/3, APO, and BW, and well as the option to have internet access. © SAP AG. SCM300. Appendix-8.
(10) Components in the Planning and Production Areas Enterprise Portals: integrated access to all components. R/3. BW. .... SAP BW. APO. SAP R/3. Core Interface. Plug-In Reporting. SAP AG 2002. SAP APO. Customer requirements management Production planning in the plant Production processing. Requirements forecast Plant-wide planning Quantity and capacity requirements planning Optimization. .... .... The SCM key areas Planning and Production mainly use the following mySAP components: SAP R/3 SAP APO (Advanced Planner and Optimizer) SAP BW (Business Information Warehouse) A plug-in allows for the interfaces responsible for the integration of R/3 with BW or APO. The interface between R/3 and APO is called a core interface (CIF).. © SAP AG. SCM300. Appendix-9.
(11) Integration of Production in Planning. SCM Planning. Plnd ind. reqmts. Demand program. Cust. reqmts. Stock. MRP. B A C D E. Planned order. Goods issue of comp. Execution of production Goods receipt of product. Purchase requisition. SCM External Procurement. SCM Production. Work scheduling. Purchase order. Goods receipt. Capacity requirements planning. Sales. Material forecast. Invoice receipt. Settlement SAP AG 2002. Shop floor control is a central part of a complex process starting with an independent requirement (planned or customer requirement) and ending with the goods issue of a finished product.. © SAP AG. SCM300. Appendix-10.
(12) Supply Chain Planning: Overview. R/3. LIS. APO. BW. Demand Planning (DP). Flexible Planning Standard SOP. SD. Global Availability Check (ATP). Demand Management. Supply Network Planning (SNP). Material Requirements Planning (MRP) Capacity Reqmts Planning (CRP). Production Planning and Detailed Scheduling (PP/DS) Transportation Planning (TP/VS). SCM Production / External Procurement SAP AG 2002. Planning covers several steps that are executed using different components in R/3 and/or APO. It makes sense to use both systems together for planning. The systems are integrated via the CIF interface (CIF: Core Interface). Demand planning uses past sales quantities to calculate the future demand program. Flexible planning (R3), the standard SOP (R3) or demand planning (APO-DP) can all be used to do this. Supply Network Planung (APO) allows for plant-wide planning of all procurement operations. The demand program (determination of planned independent requirements) is usually planned in R/3. However, planned independent requirements can also be determined in APO-DP. Sales orders are usually entered in the R/3 System. The ATP check of a sales order can take place globally in APO. Material requirements planning can be executed in both systems. In R/3 capacity planning is executed separately in a second step, while quantities and capacities are planned simultaneously in APO-PP/DS. Production takes place based on planned orders. Here mySAP SCM supports different production types.. © SAP AG. SCM300. Appendix-11.
(13) Master Data for Planning and Production. APO. R/3 Core Interface Master data Plant. CIF Initial data transfer / transfer of changes. Master data. Location. Customer Vendor Material master. Product. Work center / resource / capacity. Resource. Routing / master recipe and BOM. PPM. SAP AG 2002. Specific business operations for planning and shop floor control in R/3 and in APO are based on master data from Lifecycle Data Management. Lifecycle Data Management is a key area in the solution mySAP PLM (Product Lifecycle Management). The master data objects from R/3 and APO are not identical. The R/3 System is the leading system for the master data. The APO Core Interface (CIF) allows R/3 master data to be represented by the corresponding master data in APO. Both the initial transfer of data as well as the supply of changes made to data in APO are achieved via the CIF.. © SAP AG. SCM300. Appendix-12.
(14) Transaction Data for Planning and Production. APO. R/3. Transaction data. Transaction data Sales orders Planned ind. reqmts Planned orders Stocks Production orders / process orders Reservations Purchase orders. Core Interface. CIF Integration model. Orders - Production order - Replenishment order - Procurement order ... (Distinction based on ATP category). SAP AG 2002. The selection of transaction data exchanged between R/3 and APO is defined in an integration model in R/3. All R/3 transaction data is represented in APO by orders, which are distinguished using their ATP category.. © SAP AG. SCM300. Appendix-13.
(15) © SAP AG. SCM300. Appendix-14.
(16) Summary. Contents: Overview of production types Additional information. SAP AG 2002. © SAP AG. SCM300. 8-1.
(17) Course Overview Diagram. 1. Course Overview. 2. Introduction Order-Controlled Production with Production Orders. 3. 4. Order-Controlled Production with Process Orders. 5. Project-Oriented Production. 6 7 88. Repetitive Manufacturing Kanban. Summary. 8. SAP AG 2002. © SAP AG. SCM300. 8-2.
(18) Overview of Production Types (Basic Functions) SFC. Order-related production Status management Scheduling (with, w/o time) Capacity requirements Costing (standard and simultaneous costing) Cost Object Controlling Order-related Product-related Availability checks Material PRTs Capacity. Printing of shop floor papers Material staging using reservations Goods issue (manual or backflush) Confirmations of quantities, activities and time events (var. confirmation procedure Work in process (determination of unfinished prod.) Goods receipt (manual or automatic) Period-end closing Archiving and retrieval Mass processing. PI. REM. X X X X X X X. X X X X X X X. --(4) X X -X. X (1) X. X -X. (2) ---. X X X X. X X X X. (7) (6) (3) (8). X X X X X. X X X X X. (9) (5) X ---. SAP AG 2003. Legend: SFC = Shop Floor Control = shop floor production = discrete manufacturing with production orders PI = Process Industry = manufacturing with process orders REM = Repetitive Manufacturing = period-based production (1) Possible to limited extent (2) For planned order only (3) Backflush only (4) Valid period only (5) Fixed to final confirmation (6) No reservations! (7) No shop floor papers, only quantity papers (dispatch list) and operational method sheet (8) Quantities and activities only (9) For reporting point backflush only, for make-to-order only Scheduling normally does not involve checking the capacity available. For production/process orders, you can carry out finite scheduling (forwards with check of available capacity).. © SAP AG. SCM300. 8-3.
(19) Overview of Production Types (Special Functions) Production of configurable materials Production with production version Manufacture of co-products Batch number assignment Batch determination Material quantity calculation Batch-specific units of measure Resource network Resource selection Engineering change management Multi-level collective orders Assembly orders Order splitting Serial number management As-built configuration Cross-plant production Externl processing/external procurement Trigger points Phantom assemblies Discontinued parts (simple, groups). SFC. PI. X X X X X -X --X X X (5) X X X X X X X. X X X X X X X (4) X X -X X -X -X X -(7) X. REM. X X (1) (2) (3) -X ----X -(6) -X ---(8). SAP AG 2003. (1) By-products only (2) At goods receipt of finished product (3) At goods issue of components (4) Active ingredient management can be realized together with material quantity calculation (5) Cost Object Controlling for product in standard system only (6) At goods receipt using confirmations (7) Not with approved process orders (8) simple or parallel discontinuation possible. © SAP AG. SCM300. 8-4.
(20) Overview of Production Types (3). Link to process control level Interface (BAPI, RFC) Process management. SFC. PI. REM. PP-PDC --. PI-PCS X. (1) --. --. X. --. --. X. --. X X ---X. X X X X X X. X X -----. -X. X X. -X. (Control recipes, PI sheets, process messages). OPC interface Production in compliance with GMP Order approval Integration with QM Inspection during production Inspection for goods receipt Material identification Material reconciliation Batch record Batch where-used list Digital signature in production in QM SAP AG 2002. (1) Possible using BAPI. © SAP AG. SCM300. 8-5.
(21) Overview of Production Types (Integration) SFC. PI. REM. Warehouse Management System (WM). X. X. X. Transport and packaging units (HUs). X. X. X. Integration with QM Inspection during production Inspection for goods receipt. X X. X X. X X. X. X. X. Business Information Warehouse (SAP BW) (or LIS). SAP AG 2002. © SAP AG. SCM300. 8-6.
(22) Information about Follow-Up Courses (1) Courses on the production types SCM310 (Production Orders) SCM320 (Repetitive Manufacturing) SCM340 (Process Manufacturing) SCM350 (KANBAN). Follow-up courses in the production environment Courses of Product Lifecycle Management (mySAP PLM) PLM110 (Basic Data Part 1) PLM111 (Basic Data Part 2) PLM115 (Basic Data for Process Manufacturing) PLM130 (Classification System) PLM140, PLM143, PLM146 (Variant Configuration) LO720 (QM in Discrete and Repetitive Manufacturing) LO721 (QM in Process Industries) SAP AG 2003. For a complete overview of all courses offered, refer to the SAP Curriculum Plan. You can easily find this information in SAPNet.. © SAP AG. SCM300. 8-7.
(23) Information about Follow-Up Courses (2) Follow-up courses in the production environment (Cont.) Further courses of Supply Chain Management (mySAP SCM) Manufacturing SCM344 (Process Management) SCM360 (Capacity Planning) LO955 (Batch Management) External Procurement SCM500 (Processes in Procurement) LO510 (Inventory Management) Logistics Execution LO530 (Basic Processes in Warehouse Management). SAP AG 2003. © SAP AG. SCM300. 8-8.
(24) Information about Follow-Up Courses (3) Follow-up courses in the production environment (Cont.) From the Business Intelligence (mySAP BI) solution BW200 (Business Information Warehouse - Overview) From the mySAP Financials solution AC505 (Product Cost Planning) AC510 (Cost Object Controlling for Products) AC515 (Cost Object Controlling for Sales Orders). SAP AG 2003. © SAP AG. SCM300. 8-9.
(25) Information on the Internet (1) SAP Help Portal http://help.sap.com/. SAP Service Marketplace http://service.sap.com/. mySAP Supply Chain Management http://www.sap.com/scm/. SAP Educational Services http:// www.sap.com/education/. Internet Demo and Evaluation System http:// www.sap.com/ides/. SAP Shop http:// www.sap.com/shop/. SAP AG 2003. © SAP AG. SCM300. 8-10.
(26) Information on the Internet (2) Software partners http://www.sap.com/partners/software/ SCM interfaces: http://(…)/software/integration-opportunities/ interface-certification/scm/ (…) PI-PCS (Process control systems PI): http://(…)/scm/pi-pcs.asp (…) PP-CC2 (Process control systems PP): http://(…)/scm/pdc-cc2.asp (…) PP-PDC (Process control systems PP): http://(…)/scm/pp-pdc.asp QM-IDI (Laboratory information systems QM): http://(…)/software/integration-opportunities /interface-certification/plm/qm-idi.asp ArchiveLink (Archiving products BC): http://(…)/software/integration-opportunities/ interface-certification/technology/bc-al.asp SAP AG 2002. © SAP AG. SCM300. 8-11.
(27) References (1). Books See SAP Shop under Global SAP Knowledge Shop. SAP AG 2002. © SAP AG. SCM300. 8-12.
(28) References (2) Participant handbook for SCM300 (as course basis). Online system documentation (CD-ROM) Model company IDES (brochure). SAP AG 2002. © SAP AG. SCM300. 8-13.
(29) © SAP AG. SCM300. 8-14.
(30) Kanban. Contents: Kanban principle Mapping the principle to the system Supply areas Production supply using control cycles Procurement triggering Goods receipt Special type: event-driven kanban. Summary. SAP AG 2002. © SAP AG. SCM300. 7-1.
(31) Kanban: Unit Objectives. At the conclusion of this unit, you will be able to: Explain the characteristics of the kanban principle Describe the main steps of kanban processing List the main functions of the kanban principle. SAP AG 2002. © SAP AG. SCM300. 7-2.
(32) Course Overview Diagram. 1. Course Overview. 2. Introduction Order-Controlled Production with Production Orders. 3. 4. Order-Controlled Production with Process Orders. 5. Project-Oriented Production. 6 77 8. Repetitive Manufacturing Kanban. 7. Summary. SAP AG 2002. © SAP AG. SCM300. 7-3.
(33) Main Business Scenario. A characteristic of your company’s production is a relatively constant consumption of materials. For this reason, you want to handle the material flow to the work centers in production of your company in an event-driven manner. You organize replenishment via stock transfers, external procurement, and in-house production using the mySAP SCM kanban functions.. SAP AG 2002. © SAP AG. SCM300. 7-4.
(34) Kanban Principle. Demand source. Supply source. Full l Ful. Material. l Ful. Empty. Kanban = card. SAP AG 2002. In KANBAN, material flow is organized using containers, which are kept directly at the appropriate work centers in production. Each contains the quantity of material that work center personnel need for a certain period of time. As soon as a container is emptied at the demand source, replenishment is initiated. The supply source for the required material can be another place in the production, an external supplier or a warehouse. The demand source can use material from other containers until the actual container returns to full. The aim is for the replenishment process to be controlled from production itself, and to reduce the manual tasks required of personnel as much as possible. This self-management process and the fact that replenishment elements are created close to the time they are actually consumed means that stocks are reduced and lead times shortened (replenishment is only triggered when a material is actually required and not before). Basically, in KANBAN, material is provided in production exactly where it is required. It remains there, in small material buffers, ready for use. Thus, material staging does not need to be planned. Instead, material that is consumed is replenished immediately using KANBAN. A further advantage of KANBAN together with the SAP R/3 System is that replenishment data is transmitted to a great extent automatically. That is, scanning the barcode on a Kanban card suffices to transmit the data needed for procurement and to post the goods receipt upon receipt of the material.. © SAP AG. SCM300. 7-5.
(35) Kanban: Characteristics Features of R/3 kanban processing Pull production supported by the graphical kanban board Material flow organized using containers: Setting to Empty triggers procurement in the system Setting to Full posts the goods receipt in the system. Master data in the control cycle guarantees self-management of the production process (JIT call), therefore, material staging is not planned Minimization of the manual posting effort and administrative effort in the system Lean Manufacturing: process optimization with more employee responsibility. SAP AG 2002. © SAP AG. SCM300. 7-6.
(36) Using Kanban in Production Requirements Settlement. 1. 9. Resource planning. 2. 8 Goods receipt. l Ful. Confirmation, WIP determination. 3. l Ful. Availability check. 4. 7. Printing papers. 5. 6. Material staging using kanban. Production execution. SAP AG 2002. In the general production process, the kanban principle is used within material staging.. © SAP AG. SCM300. 7-7.
(37) Master Data: Supply Area. Supply area 3 E Supply area 2. D C. Supply area 1 B. Production Assign storage location SA Assign person responsible Unloading point for ext. procurement. Where should which material be staged? Which supply areas are necessary? SAP AG 2002. Structure and organization of production are important when introducing KANBAN. With KANBAN, material is staged directly in production in specific areas, known as supply areas. A supply area can be used by one or more work centers. The supply areas act as a buffer for the necessary materials (for example, on shelves or in marked-out areas on the floor). The supply areas established for the shop floor are defined in the SAP R/3 System in the KANBAN menu. In the definition, the supply area is assigned the following objects: The supply area is a data object used to organize material flow for KANBAN, but is not an inventory management object. Therefore, storage locations are assigned to the supply areas. Inventory management (which is relevant, for example, for posting goods receipts) therefore takes place at the storage location to which the supply area is assigned. Another significant organizational prerequisite is that you create a person responsible per supply area. If a responsible person is assigned to a supply area, this defines who is responsible at the demand source for material processing and for monitoring stocks at the supply area. If in in-house production, a person responsible is maintained in the control cycle, this defines who is responsible at the supply source for replenishment, that is, for material provision and, if necessary, for delivery to the demand source. The person responsible is assigned as an MRP controller to the supply area in Customizing for MRP. Unloading point: Often in external procurement, the supplier does not deliver the material directly to the supply area in production but to a certain unloading point. From here, the kanbans are transported to the supply area. The unloading point defines where the supplier has to deliver the material (for example, gate 1). It is printed on the kanban card or even transferred to the summarized JIT call. Delivery address: You can maintain an address in the supply area. When creating a control cycle, this address is transferred to the delivery address of the control cycle. © SAP AG. SCM300. 7-8.
(38) Master Data: Kanban Control Cycle. Demand source. Supply source. Supply area Delivery. Control cycle. Person responsible Vendor Issuing plant Warehouse. Requirement. The control cycle contains the data required for replenishing a material at a supply area (for example, number of kanbans, quantity per kanban, supply source, type of replenishment). SAP AG 2002. To control the relationship between supply and demand source, you define a control cycle. The control cycle defines: The demand source (supply area) The replenishment strategy (for example, replenishment via purchase order for external procurement or via run schedule quantities for in-house production or via stock transfer reservations for stock transfer) The supply source (supplier (vendor) or issuing plant for external procurement, the responsible person for in-house production, the storage location for stock transfer) The number of containers (kanbans) circulating between the demand and the supply source The quantity per container The delivery address (when accessing the function, the plant address is automatically maintained). Here, you can also enter detailed information required for the supply area. You can print this data on a kanban, for example). Printing parameters for printing the kanban The pallet position: More precise specification of the material's position (for example, a specific shelf section) in the supply area. The pallet position can also be printed on the kanban. Parameters for the automatic kanban calculation You can also delete or lock kanbans in the control cycle. You lock a kanban, for example, if it is not to be used for a certain time as consumption within the control cycle has fallen. © SAP AG. SCM300. 7-9.
(39) Production Supply Using Control Cycles. Control cycle D 75. 75. H 10. 10. SA_Preprod. 1. SA_Assembly 1 SA_Assembly 2 G 75. 75. E 10. 10. F 25. 25. 75. B 10. 10. E 25. 25. Vendor 1 SA_Preprod. 2. Work centers in supply areas Materials. SAP AG 2002. A 75. Central warehouse. E 75. 75. C 10. 10. Container with 10 pieces. Vendor 2. When using KANBAN, warehouses or vendors are linked to the supply areas that are assigned to the relevant producion storage locations using control cycles. Since the link to material staging can also take place via in-house production within KANBAN, preassembly and final assembly can, for example, be linked using KANBAN.. © SAP AG. SCM300. 7-10.
(40) Setting the Kanban to Empty = Triggering Replenishment. Production process. l Ful. Supply area. Empty. Supply source. Status to Empty. Ext. procurement. Stock transfer. Replenishment is triggered automatically: • Order • Purch. Purch. order .... In-house production. SAP AG 2002. The progress of production in KANBAN is controlled by setting the kanban to the appropriate status. Usually, only the two statuses, Empty and Full are used. If the demand source sets the status to Empty, the system creates a replenishment element, instructing the material supply source to deliver. Emptying a kanban does not lead to a goods issue posting! In KANBAN, goods issues are typically backflushed when an order is confirmed (or during manual goods issue posting of an order). You can set the status to Empty by scanning a bar code on the kanban card. To do this, you scan the bar code using a standard bar code scanner in the transaction Kanban Signal -> Bar Code. You can also set the status to Empty using transaction Manual Kanban Signal or in the kanban board.. © SAP AG. SCM300. 7-11.
(41) Setting Kanban to Full = Posting Goods Receipt. Production process. l Ful. Goods receipt is posted automatically. Supply area Full. Status to Full. Supply source. Full KANBAN. Ext. procurement. Stock transfer. In-house production. SAP AG 2002. If the demand source sets the status to Full, the system automatically posts the goods receipt for the material with reference to the procurement element. You can set the status to Full by scanning a bar code on the kanban card. To do this, you scan the bar code using a standard bar code scanner in the transaction Kanban Signal -> Bar Code. You can also set the status to Full using transaction Manual Kanban Signal or in the kanban board.. © SAP AG. SCM300. 7-12.
(42) Requesting Additional Kanban Containers. Event Event. Create kanban with status Empty and a predefined quantity Supply source receives request to deliver a kanban. Empty. Full. Material delivery: demand source sets status to Full. Demand source sets status back to Empty: kanban is deleted SAP AG 2002. Use: In event-driven KANBANB, material staging is not based on a predefined number of kanbans or a predefined kanban quantity (as in classic KANBAN). Instead, it is based on actual material consumption. The material is not continually provided and replenished at a supply area. It is only replenished when specifically requested. This procedure is especially useful if, for example, requirements for a particular material are irregular, but you still want to use the benefits of KANBAN to carry out replenishment with a simplified procedure. Prerequisite: You must maintain separate control cycles for event-driven KANBAN. In event-driven KANBAN, you can also use all the functions available in the KANBAN component.. Activities: 1. With the transaction Event-driven KANBAN, or the pull list, one or more kanbans are created. The quantity or the number of kanbans depends on the required quantity and the specifications in the control cycle. A replenishment element is created for each kanban created depending on the strategy. 2. Replenishment is carried out. 3. The kanban is set to Full and, if necessary, a goods receipt is posted. 4. When you set the kanban to Empty (for example, using either a bar code or the kanban board), the system deletes the kanban. 5. A new kanban is not created again until you retrigger the kanban signal using the Event-Driven Kanban function.. © SAP AG. SCM300. 7-13.
(43) Plan-Controlled Production vs Kanban. Focus of the Kanban procedure. Focus of plan-controlled production - Planning instrument. - Short-term replenishment control. - Short- to long-term requirements forecast. - Demand-based. - Date-oriented. - Event-driven. - BOM explosion. - Simple method of organization. - Lot-size calculation / optimization. - Replenishment quantity = current requirements. - Centralized planning and control. - Delivery directly to demand source. - Centralized stock responsibility. - Decentralized stock and procurement responsibility. - Push principle. - Pull principle. SAP AG 2002. Advantages of KANBAN: KANBAN is a simple form of production control: the production controls replenishment itself, to a large extent. Manual posting effort is kept to a minimum. The material is available directly on the shop floor. This saves the organizational effort required to stage the material. The production quantities correspond to actual requirements. This self-management process and the fact that replenishment elements are created close to the time they are actually consumed means that stocks are reduced and lead times shortened (replenishment is only triggered when a material is actually required and not before).. © SAP AG. SCM300. 7-14.
(44) Kanban: Summary. The kanban procedure enables material staging in production without external control effort. Material supply sources can be embedded in the self regulatingkanban control cycle, providing the material via in-house production, external procurement, or stock transfer.. . SAP AG 2002. © SAP AG. SCM300. 7-15.
(45) © SAP AG. SCM300. 7-16.
(46) Repetitive Manufacturing Contents: Application areas and characteristics Processes Mapping repetitive manufacturing onto the system Master Data Integration with planning (R/3 or APO) Planning Line Loading Material staging Backflush and Goods Receipt Special cases Settlement Information Systems. Summary SAP AG 2003. © SAP AG. SCM300. 6-1.
(47) Repetitive Manufacturing: Unit Objectives. At the conclusion of this unit, you will be able to: Explain the characteristics of period-based repetitive manufacturing Describe the main steps of repetitive manufacturing Explain the main functions within repetitive manufacturing. SAP AG 2002. © SAP AG. SCM300. 6-2.
(48) Course Overview Diagram. 1. Course Overview. 2. Introduction Order-Controlled Production with Production Orders. 3. 4. Order-Controlled Production with Process Orders. 5. Project-Oriented Production. 66 7 8. Repetitive Manufacturing. 6. Kanban. Summary. SAP AG 2002. © SAP AG. SCM300. 6-3.
(49) Main Business Scenario Your company produces products in large numbers. The production is quantity-based and period-based. You belong to the team that is implementing repetitive manufacturing for quantity-based and period-based production during the mySAP SCM implementation. Before implementation, you must create the whole process chain for in-house production, which will allow your company to organize, control, and execute production based on the mySAP SCM functions. Important stages of repetitive manufacturing are the dispatching of quantities at the production lines, material staging of the components, backflush of quantities produced, and settlement of the costs collector. These functions are integrated with other areas in your company, such as controlling and warehouse management. Therefore, you must consider the many integration relationships when implementing repetitive manufacturing. SAP AG 2002. © SAP AG. SCM300. 6-4.
(50) Application Areas Typical Typical industries industries. PRODUCT COMPLEXITY. Mechanical engineering, consumer products, electronics, and more. Takt-based Takt-based flow flow manufacmanufacturing turing. Period-based production. Mass production. PRODUCT STABILITY SAP AG 2002. Repetitive manufacturing is mainly used for production with high product stability and high repetition rate as well as low product complexity.. © SAP AG. SCM300. 6-5.
(51) Period-Based Repetitive Manufacturing: Characteristics (1) Repetitive Manufacturing Order type: - without order Quantity- and period-based production. Integration of Repetitive Manufacturing Master Data Management Sales Production or Material Requirements Planning Capacity Requirements Planning Materials Management Logistics Execution Quality Management Controlling Business Information Warehouse Logistics Information System. (mySAP PLM) (mySAP CRM, SAP R/3-SD) (SAP R/3, SAP APO) (SAP R/3, SAP APO) (SAP R/3 IM) (SAP R/3 WM) (SAP R/3 QM) (SAP R/3 CO) (SAP BW) or (SAP R/3 LIS). SAP AG 2002. © SAP AG. SCM300. 6-6.
(52) Period-Based Repetitive Manufacturing: Characteristics (2) Basic Functions of Repetitive Manufacturing Scheduling Calculation and monitoring of capacity requirements Costing Availability checks Printing of dispatch list and operational method sheet Material staging (without reservations!) Goods issue: component backflushing by default Goods receipt: closely linked to final confirmation (quantities and activities) Period-end closing (process cost allocation, overhead rates, WIP determination, variance calculation, cost collector settlement). SAP AG 2002. Apart from the basic functions, repetitive manufacturing offers several other functions (see next slide). The course SCM320 covers a selection of the most important of these functions in detail.. © SAP AG. SCM300. 6-7.
(53) Period-Based Repetitive Manufacturing: Characteristics (3) Enhanced Functions of Repetitive Manufacturing Printing of operational method sheet and dispatch list with Microsoft Office link Reporting point backflush (milestone) Action control Mapping of takting to the system using takt-based flow manufacturing. SAP AG 2002. There is an MS Office link for the printing of shop papers and quantity papers (no shop floor papers!): MS Word can be used to print operational method sheets and MS Excel for print dispatch lists. Beside make-to-stock production, sales-order-oriented repetitive manufacturing is also supported. This enables, for example, dealing with configurable materials. To determine work in progress or to post component withdrawals timelier, you can use a reporting point procedure (only make-to-stock). With regard to configurable materials, action control enables the automatic triggering of actions (for example, printing the component list). The modelling of takts along with the sequence planning it involves is represented by a separate function: takt-based flow manufacturing.. © SAP AG. SCM300. 6-8.
(54) Costing. Demand program. Material forecast. SD. Indep.reqmts. Sales orders Stock. Planned orders. MRP Rep. Manufacturing. B A C D E. Planned orders (RSQ) Manufacturing. Confirmation w. stock receipt Settlement of cost collector. Integration with QM. Inventory management. Capacity requirements planning. Application-wide processes. Integration with PDC. SAP AG 2003. The complex process chain from independent requirements to the goods issue of the finished product is reproduced in a lean version in repetitive manufacturing. Typical features are, for example, the use of planned orders for production (Planned orders are not converted to production orders. They only obtain the new order type run schedule quantity (RSQ) when the production version is assigned.) as well as the confirmation of the finished product with simultaneous backflushing of the components used.. © SAP AG. SCM300. 6-9.
(55) Master Data for Repetitive Manufacturing Repetitive mfg indicator and REM profile. Material. Production version. BOM. BOM. Material BOM. Production line as work center (or as an exception, as a line hierarchy). Work center. Rate routing (or standard routing) Routing. Routing. Usually one operation Definition of production rate (quantity per time). SAP AG 2002. To allow a material for repetitive manufacturing, you set the Repetitive Mfg indicator in the material master record (in the MRP4 view). This means you can use all the various production versions of this material for repetitive manufacturing (that is, you can set the indicator Repetitive Mfg allowed for version in the production version). The BOM defines the planned material consumption for the components. In the status/long text of the BOM item (Production storage location field), you can define the issue storage location from which components are to be backflushed. Production lines are usually created as simple work centers in SAP R/3. In the work center, you define from when and to when the production line is available. The production line created as the work center is entered in the production version in the Production line field. This same work center is specified in the single operation of the routing. Production lines that have more than one work center can be represented in a line hierarchy. In repetitive manufacturing, the routing defines the production rate (quantity per time unit) used to produce materials on production lines. The production quantities are scheduled according to the production rate, and capacity requirements are calculated for this production quantity. The routing therefore provides the basis for lead time scheduling. In repetitive manufacturing, work centers are not usually used to describe the actual operations to be performed. Therefore, routings in repetitive manufacturing often only have one operation. The total production rate of the line is specified in this operation. It defines how many materials per time unit can be produced on this production line. In the single operation, you enter the production line as the work center. Two different routings are available in SAP R/3: standard routings and rate routings. Rate routings are specially designed for the needs of repetitive manufacturers and can be used instead of standard routings for organizational purposes. You can, however, also use standard routings for repetitive manufacturing. © SAP AG. SCM300. 6-10.
(56) Demo Scenario: PC Production in the Dresden Plant Sales orders SD. Finished goods warehouse 0002. Confirmation Line T-L1##. Sold-to party PC final assembly. Stor. location PL01 Confirmation Line T-L3## Assembly production Stor. location PL03. Stor. location PL04. Material staging by stock transfer. Vendors. Material warehouse 0001. Plant 1200 (Dresden). SAP AG 2002. Demonstration example for repetitive manufacturing: In plant 1200, PCs and PC assemblies are produced. The most important material numbers used for the demo and exercises in the training system are: T-F10## PC Maxitec R-375 (Final assembly with make-to-order production) T-B10## Motherboard M-375 (Assembly production to stock) T-B20## Cable with earthed plug T-B30## Keyboard T-B40## TFT Monitor T-B50## Diskette drive T-B60## Harddisk T-B70## PC case T-B80## CD ROM drive T-B90## Modem T-T6## Memory (for pull list: direct transfer posting) T-TE## Processor M-375 Production lines: T-L1## Production line 1 (for production T-F10##) T-L3## Production line 3 (for production T-B10##). © SAP AG. SCM300. 6-11.
(57) Repetitive Manufacturing: Process Flow. Settlement by product cost collector. Requirements. 1. 10. Planning of line loading and capacity check. 2. 9 Final confirmation and stock receipt with component backflushing. 3. 4 WIP determination (optional with reporting point backflush). 5. 8. Availability check Printing of operational method sheet Printing of dispatch list. 6. 7. Material staging. Production execution SAP AG 2002. Despite the lean implementation of basic functions, a number of activities are possible in repetitive manufacturing. The main aspects are the planning of line loading and the (usually simultaneous) capacity monitoring. You can, for example, use the planning table (multi-level access) to check the availability of assemblies for the finished product. The worker gets the information he or she needs from the operational method sheet (description of the operation if necessary) and from the dispatch list (materials, quantities, and dates). Material staging is done by stock transfers or KANBAN provision to the line. During production, reporting point backflush can be used to determine work in progress. After order processing, the finished product is confirmed to stock. This means both the goods receipt as well as the component backflush is posted. Costs are settled by means of a product cost colletor.. © SAP AG. SCM300. 6-12.
(58) Integration with Planning (R/3 or APO). APO. R/3. Demand Planning (DP). Flexible Planning Demand Management. Plnd indep.reqmt. Plnd indep.reqmt Consumption. Sales (SD). Sales order. Production Planning (PP) MRP. Sales order. Supply Network Planning (SNP) Production Planning (PP/DS). Planned order Repetitive Manufacturing. Planned order (RSQ). Purchasing Purchase requisition Purchase order (MM) Stock transp. requisition Stock transport order. Planned order or run schedule quantity. Assign Planned order to line. Purchase requisition Purchase order. Conversion. Stock transp. requisition Stock transport order. Deployment. SAP AG 2003. The mySAP SCM solution offers two general solution methods for integrating planning and production: planning with the functions of the APO component and planning with the functions of the R/3 component. Production preparation, execution,and control is always carried out with the functions of the SAP R/3 component, but also depending on the production type. These functions include costing, material staging, confirmation, goods movements, and settlement. Other functions (scheduling, availability check, machine commitment, for example) can be performed using either of the SAP components. Between the two SAP components, the master data and transaction data (planned orders, production orders, purchase requisitions, purchase orders, stocks, and so on) is usually exchanged via the Core Interface (CIF). Specific events lead to the transfer of data from R/3 to APO (release, confirmation, goods receipt) and vice versa. Sales orders are usually entered in R/3 and transferred from there to APO. Planned orders can be generated in material requirements planning in R/3 (MRP) or in APO with the following: a) Supply Network Planning in APO (SNP) This component achieves cross-plant planning in a long-term planning horizon across the whole supply and procurement chain. Stock transport requisitions (distribution), planned orders (in-house production), and purchase requisitions (external procurement) are generated for each production plant. b) Production Planning and Detailed Scheduling APO (PP/DS) This component generates planned orders and purchase requisitions in a defined, short-term time period (production horizon) in the production plant. What distinguishes repetitive manufacturing is that planned orders with order type RSQ (run schedule quantity) are used for production, which means that planned orders are not converted. Only their status changes when they are assigned to the production line. © SAP AG. SCM300. 6-13.
(59) Basic Planning Strategies for Repetitive Manufacturing Make-to-stock production Sales order. SD. Demand Management. Warehouse stock Production line. Make-to-order production (sales order-based production) Sales order Sales order. Sales order stock. SD. Production line Configurable materials also possible SAP AG 2002. Make-to-stock production: You can use repetitive/flow manufacturing for pure make-to-stock production. This means you produce products with no direct reference to sales orders. The planned independent requirements from demand management are used as the basis for planning. Depending on your planning strategy, the planned independent requirements from demand management can be consumed by sales orders. The same product is produced repeatedly over a substantial period of time. The product is not produced in lots. Instead, a total quantity is produced in a certain period at a certain rate. Products pass through production in a relatively steady flow. Sales orders are filled from warehouse stock. Make-to-order production (sales order-based production): You can use repetitive/flow manufacturing for make-to-order production. This means you produce products with direct reference to the sales orders. The products are stored in the sales order stock. Sales orders can be processed separately. A planned order is created with direct reference to the sales order. Production is therefore controlled using sales orders. The quantities produced cannot be swapped between the individual sales orders. The produced quantities are stored specifically for the individual sales order (sales order stock) and not in the anonymous warehouse stock. If you use variant configuration, you can plan and manufacture configurable materials using make-to-order repetitive manufacturing. Sales orders are filled from sales order stock. Prerequisite: You use the strategy group in the material master record to control whether you want to use make-to-stock or make-to-order repetitive manufacturing.. © SAP AG. SCM300. 6-14.
(60) Planning Line Loading: Overview. PlOrd.. PlOrd.. PlOrd.. PlOrd. PlOrd. Planned order assignment using... Optionally R/3 planning table/ APO product planning table. Alternative selection (automatically) Quota arrangement (automatically). SAP AG 2003. You can use any of the following three options to plan the line loading (dispatching of planned orders on the production line): Alternative selection: - If only one valid production version, that is, for example, only one line, is available, you can set the alternative selection indicator 2 in the material master (MRP4 view). Planned orders are then automatically assigned to this line. If several lines are available, the system assigns the first line it finds. Since this reduces your freedom when planning the line loading, we recommend using this option only if there is only one valid production version or production line. Quota arrangement: - If several production lines are available but one is preferred (for example, it is always to reach full capacity load), you can use quota arrangements to distribute the remaining quantity to the alternative lines. To do so, you maintain the Quota arr. usage field in the MRP2 view in the material master and trigger quota maintenance in the MRP menu under Master Data. We recommend using quota arrangements only for rough-cut planning with additional postprocessing in the planning table. R/3 planning table/APO product planning table: - As opposed to the other methods, quantities are dispatched manually or semiautomatically on the available lines when planned orders are assigned in the R/3 planning table or the APO planning table. © SAP AG. SCM300. 6-15.
(61) Actions for Manual Planning of Line Loading (Example: R/3) Capacity data Line 1 Requirement Available Line 2 Requirement Available. % h h % h h. Material data Material A Requirements Available qty Production line 1 Production line 2 Not yet assigned. PC PC PC PC PC. Due. 04.09.. 0 0 16 0 0 16. 100 16 16 0 0 16. Due. 04.09.. 200. 100 200 100. 0. 200. 05.09. 50 8 16 150 24 16. Monitoring: Capacity utilization. 05.09. Activitiy: Assign lines 50 150 0. SAP AG 2003. The planner uses the R/3 planning table to process the master plan. He or she can check the production quantities, change them if required, and create new production quantities (planned orders). He or she can determine the capacity utilization of the production line as well as the availability situation of the products. In addition, he or she can display the source of the capacity requirements (pegged capacity) by double-clicking the capacity requirements. Since planning in repetitive manufacturing is carried out in a quantity- and period-based manner, the display in the planning table is quantity- and period-based. You can choose any planning period (shift, day, week, month, planning calendar period). In the assignment mode, the planner can assign the production quantities (planned orders) to a production version and thus to a production line. If this was already done in MRP, he or she can also change existing assignments. Planned orders that are assigned manually to a line obtain order type PE (run schedule quantity) and are usually fixed. By means of the repetitive manufacturing profile, the fixing behavior can be limited to the planning time fence per material or deactivated in general. In addition, you can choose Materials Overview to go to a separate material overview displaying the exception message and range of coverage situation. Changes you make in the planning table are not written to the database unless you save them. In the SAP APO System, similar functions are available in the product planning table. It is an enhancement of the R/3 planning table and serves as the manual planning tool in SAP APO according to the enhanced APO planning functions. The graphic illustrates the general appearance of the R/3 planning tool. In an illustration of the APO product planning table, the terms Material and Line/Capacity would have to be replaced by Product and Resource. © SAP AG. SCM300. 6-16.
(62) Material Staging Options Pull list: Staging from storage location level. MM-IM Warehouse Mgmt Inventory Management. List of kanbans to be moved Pull list: event-driven kanban. Kanban control. Pull list: List of transfer requirements Transfer orders. LE-WM Warehouse Mgmt System. Material is ordered. Release order parts Pick parts. Prod. order. Order-based creation of transfer requirements Container is ordered. Crate parts SAP AG 2002. The SAP R/3 System has various procedures for controlling material staging. a) Warehouse management with the component MM-IM (Inventory Management) b) Replenishment control with the component KANBAN c) Handling of storage bins and replenishment control with the component LE-WM (Warehouse Management) The pull list enables processing by means of transfer postings on the storage location level, supports event-driven KANBAN, and enables integrating Warehouse Management (WM). Since pick part processing is order-based, the Warehouse Management System prefers to use release order parts for non order-based repetitive manufacturing: Release order parts are ordered manually. Here the required quantity is calculated from the target quantity of the components of the selected orders that have been released. Both pick part processing and crate part processing can be used when the typical repetitive manufacturing functions (for example, the planning table) are used by means of production orders.. © SAP AG. SCM300. 6-17.
(63) Backflush and Goods Receipt. Upload PDC interface. Manual entry Product cost collector. Goods receipt of finished products. Saving backflushes. Standard actions using backflushing data. Goods issue of components. Update statistics. Production costs. Reduction of PL Ord.. SAP AG 2003. The BAPI interface can be used for backflushing from PDC systems. A separate transaction (MFBF) is available for manual entry of backflushes in the SAP R/3 System. By posting the goods receipt for the finished products during backflushing a number of different actions are performed by default (controlled by the repetitive manufacturing profile): Goods issue posting for the components used (usually by backflushing) Statistics update in the Logistics Information System (LIS) or the Business Information Warehouse (BW) Reduction of run schedule quantities/planned orders and the connected capacity requirements on the production lines Posting of production costs incurred (material costs, production activities, overhead costs) to a product cost collector Data entry document creation Other optional actions (see Details in the REM backflush transaction) include the following: consideration of setup costs for lot-size independent material quantities, posting of component/assembly scrap, collective entry for different materials of a line, archiving of backflush documents, pure goods issue backflush or pure activity backflush (more/less activity), reporting point backflush, decoupled backflushing processes, aggregation as well as various postprocessing and reversal options. In addition, sales-order based production enables backflushing with reference to the sales order. © SAP AG. SCM300. 6-18.
(64) Reporting Point Backflush Example:. Production line 1 Work center 1-1. Operation 10. Work center 1-2. Work center 1-3. Receiving storage location Work center 1-4. Goods receipt. Operation 20 Operation 30 Operation 40. Goods issues Issuing storage location. Issuing storage location. Report. point backflush Report. point backflush. Report. point backflush with GR. SAP AG 2002. Scenario: A long production line with longer lead time exists. However, the goods issues for the first components at work centers 1-1 and 1-2 are to be posted timely and not by backflushing with final confirmation at the end of the production line. During final confirmation, all components used along the production line are usually backflushed. If there are long lead times, the goods issues for the components may be posted much later in the system than after they have actually been withdrawn physically. In this case, it makes sense to use the reporting point backflush to timelier post the withdrawal of components (and production activities) after operations already completed. The above example contains the three reporting points connected with operations 10 (work center 1-1), 20 (work center 1-2), and 40 (work center 1-4). Prerequisite: In addition to having activated reporting point backflush in the repetitive manufacturing profile, the relevant work centers must exist, and the operations must be available in the routing and defined as reporting points by means of the control key. Depending on the application, optional or required reporting point backflush is possible and makes sense.. © SAP AG. SCM300. 6-19.
(65) Action Control. Example: Printing the component list for configurable material. Action control Printing component list for planned order. Components available?. Issuing storage location 1. SAP AG 2002. The Actions in planned order function provides a solution for an interface to external assembly control systems. This is used to transfer progress at the assembly line and other dependent actions to the SAP System using a standard interface or an adjusted interface. The following standard functions are available: BEMA BOM explosion with availability check, BFPL Backflush planned order, BOME BOM explosion, COPD Change planned order data (e.g. sequence number, order quantity), DLPL Delete planned order, FIKM Firm planned order components, FIRM Firm planned order header, MAAV Availability check with BOM explosion if necessary, NEMA Availability check without BOM explosion, PRNT Print component list, RSMA Reset material availability check, SCHE Scheduling planned orders, Execution of custer-defined actions, ZZXX Customer action. You can use this function to execute one or more actions for a series of planned order simultaneously. Without this function, you would have to execute these actions individually per planned order online. Furthermore, action control defines which actions are allowed and the sequence in which the actions are to be carried out The date and the time of the last action are then saved in the planned order. Executing actions: To execute actions, you must maintain a report that transfers the customer-specific data for the action. You can use the Execute Action transaction in the MRP menu as an example. To print the planned order component list, the system uses the printer defined in Customizing for MRP in the activity Procurement Proposals -> Planned Orders -> Define Layout for Component List.. © SAP AG. SCM300. 6-20.
(66) Cost Debit / Credit (Product-Related COC) Debit product cost collector Material cost Production costs Overhead costs to material. Costing document from material costing. Product cost collector M 1000 100-100 E 1421 4230 1310 G Surcharge, raw material. 12,000 25,000 8,500. E ... 25.000 12 11 1 10 2 9 3 8 4 7 6 5. Material withdrawal. Processing Processing. Confirmation. Goods receipt. Settlement Settlement. Credit Credit product product cost cost collector collector GR valuation control. Settlement profile Settlement receiver. Material stock account (quantity * standard/price acc. to valuation variant) Plant activity account (quantity * price acc. to valuation variant). SAP AG 2002. Actual costs at time of settlement. Distribution rule Settlement parameters Settlement account (acc. to allocation structure) Plant activity account Difference account. Settlement in repetitive manufacturing is always period-based based on the costs of the product cost collector (product-related cost object controlling). When executing confirmations in repetitive manufacturing, the material costs for the components and the production activities (only if a material cost estimate with price update was carried out in advance) are automatically posted to the product costs collector during backflushing. The product cost collector is debited with the material costs and production activities (in the repetitive manufacturing profile, you can define whether activity backflush is to be made with reference to the material cost estimate or the version-specific cost estimate). Morevover, the product cost collector is credited with the valuation price (materials controlled with standard price) or with the moving average price of the assembly (materials controlled with the moving average price). Overheads are not determined with reference to an operation (that is, not for each goods movement or activity confirmation). Instead they are determined periodically during period-end closing in Controlling by way of an overhead structure and are posted to the product cost collector. There is a separate transaction in the Repetitive Manufacturing menu for this. It is possible that components different to those planned are used in production or that the overhead cost rates change. This results in variances in the product cost collector and settlement must be executed. The aim of settlement is to completely credit the product cost collector. During settlement, the costs not yet credited to the product cost collector are transferred; for a material that is valuated using the standard price, the variant costs are posted to the price difference account. © SAP AG. SCM300. 6-21.
(67) Integration with Controlling Prerequisites for cost settlement: Creating a product cost collector (either per material or also per production version) The posting of production activities must have been defined accordingly in the REM profile. In addition, a material cost estimate with price update must be made. Besides the material cost estimate, version-specific preliminary costing is possible if several production versions are used (can be activated in the REM profile) Carrying out cost settlement: Debiting the product cost collector with the material costs, production activities, and overhead costs incurred Crediting the product cost collector to the stock account Period-based variance calculation to price difference account. SAP AG 2002. Transaction codes for the above actions: Create Product Cost Collector per Material [KKF6N], also per production version [KKF6M] Material cost estimate [CK11N] with price update (marking and release) [CK24] Preliminary cost estimate ([MF30] and [OPP3], REM profile). © SAP AG. SCM300. 6-22.
(68) Repetitive Manufacturing: Information Systems Basis Order Information System. Planned orders. Controlling reports. CO objects of orders. Business Information Warehouse (SAP BW) in mySAP BI. BW InfoCubes. Logistics Information System (R/3 LIS) statistics. R/3 LIS Library. Reporting point overview. Backflush. SAP AG 2002. Repetitive manufacturing supports different evaluation methods. Beside the analyses via CO reports, a data update is made in the Logistics Information System LIS by default (exception: planning data must be updated manually or in a background job). A link to the Business Information Warehouse (BW) also exists. Evaluations based on orders are not supported since the processing is not order-related.. © SAP AG. SCM300. 6-23.
(69) Repetitive Manufacturing: Summary. The Repetitive Manufacturing application can be used for period-based and quantity-based production control. The period quantities are planned as run schedule quantities and assigned to the production lines. The production is carried out without orders, enabling simple production control. The main tools for repetitive manufacturing are the SAP R/3 planning table and the SAP APO product planning table.. SAP AG 2002. © SAP AG. SCM300. 6-24.
(70) Exercises Unit: Repetitive Manufacturing Topic: Master Data At the conclusion of these exercises, you will be able to: • Name the main master data for repetitive manufacturing • Explain what is special about the master data for repetitive manufacturing. You work for a company that uses repetitive manufacturing to produce PCs on two production lines. You are a member of the SAP project team responsible for implementing the functions of SAP SCM Repetitive Manufacturing. You therefore first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you look at the master data for the PC T-F10## (material master, BOM, routing, and work center as well as the product cost collector from Controlling).. 1-1. First, get an overview of the menu structure for the repetitive manufacturing functions. 1-1-1 Which menu path takes you to the Repetitive Manufacturing menu? ______________________________________________________ 1-1-2 Which transactions take you to Customizing for Repetitive Manufacturing? ______________________________________________________. © SAP AG. SCM300. 6-25.
(71) 1-2. Name the basic Logistics master data for repetitive manufacturing. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________. 1-3. In the Logistics folder in the R/3 menu, navigate to the material master of PC T-F10## (## = your group number), MRP4 view, plant 1200. Use the change mode (transaction MM02). Name three material master settings that are specific to repetitive manufacturing: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ 1-3-1 Display production version 0001. Check the consistency of the combination of BOM and routing by choosing Check. 1-3-2 Which production line is entered in production version 0001? ______________________________________________________ 1-3-3 Write down the group counter of the rate routing entered: ______________________________________________________. 1-4. Check the material BOM for material T-F10##in the Logistics master data. How many assemblies are on the hierarchy level directly below the finished product? ____________________________________________________________. © SAP AG. SCM300. 6-26.
(72) 1-5. Display the rate routing for material F10##, plant 1200 in the Logistics master data. 1-5-1 How many different routings are displayed in the overview? ______________________________________________________ 1-5-2 Select the first routing with group counter 1 and choose Operations. What is special about the routing? ______________________________________________________ ______________________________________________________ 1-5-3 Name the work center involved and the production rate planned: ______________________________________________________ 1-5-4 Exit the operation overview and go back to the rate routing overview. Which work center belongs to group counter 2? ______________________________________________________ 1-5-5 Write down the group counter number and compare it with exercise 1-3-3. Note: You find the group counter number in the rate routing header data. ______________________________________________________ 1-5-6 Does production version 0001 enable repetitive manufacturing with the two routings? Give reasons. ______________________________________________________ ______________________________________________________. 1-6. In the Repetitive Manufacturing menu, check in the master data whether a product cost collector already exists for material T-F10## in plant 1200. Note: To do so, you must activate the field next to the material in the display transaction. How many product cost collectors exist and how are they assigned? ____________________________________________________________ ____________________________________________________________. © SAP AG. SCM300. 6-27.
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(74) Exercises Unit: Repetitive Manufacturing Topic: Integration with Production Planning and MRP in the R/3 System At the conclusion of these exercises, you will be able to: • Create a quantity- and period-based master production schedule for repetitive manufacturing • Interpret the results of a planning run in the stock/requirements list. In your plant 1200 in Dresden, you produce PCs. To achieve shorter delivery times, you execute planning for assembly production (make-tostock strategy) together with the Planning without final assembly strategy (make-to-order) for the finished product. This means that the last step of final assembly is made only after a corresponding sales order was received. First, check whether the master data for materials T-F10## (PC) and TB10## (motherboard) and then create planned independent requirements.. 2-1. Make sure that for the finished product T-F10## the correct settings have been made for the strategy groups in the R/3 material master (plant 1200, MRP3 view): 50 – Planning without final assembly:. 2-2. Is the material allowed for repetitive manufacturing? Note: Check the settings in the material master, MRP4 view and the release indicator (REM allowed) in the relevant production versions.. 2-3. Now create planned independent requirements for the finished product in your plant 1200: Menu path: Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Create Data: Values: Material Plant Planning period. © SAP AG. T-F10## 1200 W SCM300. 6-29.
(75) In the next screen, choose the Sched. Lines tab. Create a planned independent requirement with a requirements date for the next week (enter the calendar week in the format week.year). The planned quantity should be 600 pieces. The quantity with period indicator W is to be distributed over the individual working days. Therefore, set the T (day format) indicator in the Splt column and confirm your entry. Confirm warning messages that may be displayed and save your planned independent requirements. 2-4. A sales order is received in Sales and Distribution. Now act as if you were the sales employee and create the following sales order for the finished product T-F10##: Menu path: Logistics → Sales and Distribution → Sales → Order → Create Data:. Values:. Order type Sales organization Distribution channel Division. TA 1000 10 00. Sold-to party Purch.order no. Req.delivery date Material Quantity. 1171 660## Tuesday in two weeks T-F10## 100 pieces. Save the sales order. 2-5. Plan the BOM structure of the PC in an MRP run: Menu path: Logistics → Production → MRP → Planning – Single-Item, Multi-Level Use the following settings: Material Plant Further settings. T-F10## 1200 2, 3, 1, 1, 1. Start the MRP run by choosing Enter twice. Note: Multi-level planning ensures that secondary requirements are also created for lower BOM hierarchy levels.. © SAP AG. SCM300. 6-30.
(76) 2-6. Use the stock/requirements list for the finished product T-F10## in plant 1200 to interpret the results: Menu path: Logistics → Production → MRP → Evaluations → Stock/Requirements List Why is the plant stock for the material not included? ____________________________________________________________. 2-7. Use the stock/requirements list for assembly T-B10## in plant 1200 to interpret the results: Menu path: Logistics → Production → MRP → Evaluations → Stock/Requirements List. 2-8. Double-click a planned order to display the detail data. Why are there no pushbuttons to convert the planned order to a production order? ____________________________________________________________ ____________________________________________________________. © SAP AG. SCM300. 6-31.
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