SCM300 Manufacturing Overview
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(2) Copyright Copyright © 2009 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors.. Trademarks •. Microsoft®, WINDOWS®, NT®, EXCEL®, Word®, PowerPoint® and SQL Server® are registered trademarks of Microsoft Corporation.. •. IBM®, DB2®, OS/2®, DB2/6000®, Parallel Sysplex®, MVS/ESA®, RS/6000®, AIX®, S/390®, AS/400®, OS/390®, and OS/400® are registered trademarks of IBM Corporation.. •. ORACLE® is a registered trademark of ORACLE Corporation.. •. INFORMIX®-OnLine for SAP and INFORMIX® Dynamic ServerTM are registered trademarks of Informix Software Incorporated.. •. UNIX®, X/Open®, OSF/1®, and Motif® are registered trademarks of the Open Group.. •. Citrix®, the Citrix logo, ICA®, Program Neighborhood®, MetaFrame®, WinFrame®, VideoFrame®, MultiWin® and other Citrix product names referenced herein are trademarks of Citrix Systems, Inc.. •. HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C®, World Wide Web Consortium, Massachusetts Institute of Technology.. •. JAVA® is a registered trademark of Sun Microsystems, Inc.. •. JAVASCRIPT® is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape.. •. SAP, SAP Logo, R/2, RIVA, R/3, SAP ArchiveLink, SAP Business Workflow, WebFlow, SAP EarlyWatch, BAPI, SAPPHIRE, Management Cockpit, mySAP.com Logo and mySAP.com are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies.. Disclaimer THESE MATERIALS ARE PROVIDED BY SAP ON AN "AS IS" BASIS, AND SAP EXPRESSLY DISCLAIMS ANY AND ALL WARRANTIES, EXPRESS OR APPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO THESE MATERIALS AND THE SERVICE, INFORMATION, TEXT, GRAPHICS, LINKS, OR ANY OTHER MATERIALS AND PRODUCTS CONTAINED HEREIN. IN NO EVENT SHALL SAP BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES OF ANY KIND WHATSOEVER, INCLUDING WITHOUT LIMITATION LOST REVENUES OR LOST PROFITS, WHICH MAY RESULT FROM THE USE OF THESE MATERIALS OR INCLUDED SOFTWARE COMPONENTS.. g20093272929.
(3) About This Handbook This handbook is intended to complement the instructor-led presentation of this course, and serve as a source of reference. It is not suitable for self-study.. Typographic Conventions American English is the standard used in this handbook. The following typographic conventions are also used. Type Style. Description. Example text. Words or characters that appear on the screen. These include field names, screen titles, pushbuttons as well as menu names, paths, and options. Also used for cross-references to other documentation both internal (in this documentation) and external (in other locations, such as SAPNet).. Example text. Emphasized words or phrases in body text, titles of graphics, and tables. EXAMPLE TEXT. Names of elements in the system. These include report names, program names, transaction codes, table names, and individual key words of a programming language, when surrounded by body text, for example SELECT and INCLUDE.. Example text. Screen output. This includes file and directory names and their paths, messages, names of variables and parameters, and passages of the source text of a program.. Example text. Exact user entry. These are words and characters that you enter in the system exactly as they appear in the documentation.. <Example text>. Variable user entry. Pointed brackets indicate that you replace these words and characters with appropriate entries.. Icons in Body Text The following icons are used in this handbook.. 2009. © 2009 SAP AG. All rights reserved.. iii.
(4) About This Handbook. Icon. SCM300. Meaning For more information, tips, or background Note or further explanation of previous point Exception or caution Procedures. Indicates that the item is displayed in the instructor's presentation.. iv. © 2009 SAP AG. All rights reserved.. 2009.
(5) Contents Course Overview ......................................................... vii Course Goals ...........................................................vii Course Objectives .....................................................vii. Unit 1: Introduction........................................................ 1 Production types of the applications SAP ERP and SAP SCM ...2. Unit 2: Order-Controlled Production with Production Orders..11 Order-Controlled Production with Production Orders ............ 12 Elements, Functions, and Processing of a Production Order ... 22. Unit 3: Order-Controlled Production with Process Orders..... 81 Order-Controlled Production with Process Orders ............... 82 Elements, Functions, and Processing of a Process Order ...... 93. Unit 4: Repetitive Manufacturing .................................... 151 Characteristics of Repetitive Manufacturing......................152 Functions and Process Steps in Repetitive Manufacturing.....169. Unit 5: KANBAN ......................................................... 207 Features of the KANBAN Procedure ..............................208 The KANBAN Procedure............................................212. Unit 6: Project-Oriented Production (optional) .................. 225 Characteristics of Project-Oriented Production ..................226 Process Flow of Project-Oriented Production ....................232. Unit 7: Integration to process control level (optional) ......... 253 PP-PDC Interface ....................................................254 Process Management/Process Integration .......................259 SAP OPC Data Access .............................................266 SAP MII in Shop Floor Control .....................................272. Appendix 1: Summary Appendix 2: References. 2009. .............................................. 279 ............................................ 285. © 2009 SAP AG. All rights reserved.. v.
(6) Contents. vi. SCM300. © 2009 SAP AG. All rights reserved.. 2009.
(7) Course Overview Manufacturing is a component of the SAP SCM (Supply Chain Management) and SAP ERP (Enterprise Resource Planning) applications within the SAP Business Suite. You can use manufacturing to manage all the manufacturing activities within your supply chain in one integrated system – from planning through execution to analysis. The focus of this course is execution. The following topics are dealt with, in particular: • • • • •. Order-Controlled Production with Production Orders Order-Controlled Production with Process Orders Repetitive Manufacturing KANBAN Project-Oriented Production (optional). Target Audience This course is intended for the following audiences: •. Project team members and key users (people from relevant departments) who are responsible for implementing shop floor control within the SAP Business Suite applications. Course Prerequisites Required Knowledge •. SAPSCM: mySAP SCM Overview. Recommended Knowledge • • •. PLM100 Lifecycle Data Management SCM100 Supply Chain Planning Overview (ERP) SCM200 Supply Chain Planning Overview (SCM). Course Goals This course will prepare you to: •. •. 2009. Understand the positioning, integration, and functions of the manufacturing area within the SAP ERP (Enterprise Resource Planning) and SAP SCM (Supply Chain Management) applications Obtain an overview of the supported production types. © 2009 SAP AG. All rights reserved.. vii.
(8) Course Overview. SCM300. Course Objectives After completing this course, you will be able to: •. Describe basic shop floor control procedures and functions and understand simple scenarios in the SAP System. SAP Software Component Information The information in this course pertains to the following SAP Software Components and releases: • •. viii. ERP 6.0Enhancement Package 4 SAP SCM 7.0. © 2009 SAP AG. All rights reserved.. 2009.
(9) Unit 1 Introduction Unit Overview Manufacturing types of applications SAP ERP and SAP SCM In this unit, you will learn about the manufacturing types within the SAP Business Suite.. Unit Objectives After completing this unit, you will be able to: •. you will be able to name the production types that are supported within the SAP Business Suite.. Unit Contents Lesson: Production types of the applications SAP ERP and SAP SCM ...2. 2009. © 2009 SAP AG. All rights reserved.. 1.
(10) Unit 1: Introduction. SCM300. Lesson: Production types of the applications SAP ERP and SAP SCM Lesson Overview In this lesson, you will learn about the production types that are supported within the SAP Business Suite.. Lesson Objectives After completing this lesson, you will be able to: •. you will be able to name the production types that are supported within the SAP Business Suite.. Business Example Your company implements the SAP Business Suite. You are either a member of the project team responsible for implementing the shop floor control functions or you are in the production department. You use various scenarios to gain an overview of the possibilities and functions of the supported production types.. Overview of SAP applications. Figure 1: SAP ERP Application Overview. 2. © 2009 SAP AG. All rights reserved.. 2009.
(11) SCM300. Lesson: Production types of the applications SAP ERP and SAP SCM. As part of the long-term product strategy of SAP, you are offered an SAP Business Suite that comprises a number of applications. The Enterprise Resource Planning (ERP) application is a comprehensive application that enables a company to efficiently plan, control and monitor complex delivery, procurement and production networks. This application supports a synchronized and close interaction between all departments involved (and all people involved) within a logistics chain. Customers, sales, production planning, manufacturing, warehouse management, purchasing, and vendors are all included in this complete solution. The SAP ERP application includes a number of areas (see above). You will find further information about the individual components of the SAP ERP application at http://www.sap.com/solutions/businessmaps/solutionmaps/ and also here, under Cross-Industry Business Maps.. Figure 2: SAP SCM Application Overview. SAP Supply Chain Management (SCM) is a comprehensive application that enables a company to efficiently plan, implement and monitor complex delivery, procurement and production relationships (supply chains). This application supports a synchronized and close interaction between all departments involved (and all people involved) in a logistics chain.. 2009. © 2009 SAP AG. All rights reserved.. 3.
(12) Unit 1: Introduction. SCM300. Customers, sales, production planning, manufacturing, warehouse management, purchasing, and vendors are all included in this complete solution. In particular, the processing of cross-company processes and the collaborative planning and procurement processes, which also enable a connection to open market places, are a main feature of this application. The SAP SCM application includes a number of areas (see above). You will find further information about the individual components of the SAP SCM application at http://www.sap.com/solutions/businessmaps/solutionmaps/ and also here, under Cross-Industry Business Maps.. Figure 3: SAP Components. In-house production is largely supported by the SAP component SAP ECC (formerly R/3). SAP SCM provides considerably enhanced planning tools (Advanced Planning and Optimization (APO), an enhanced inventory function (Supply Network Collaboration (SNC)) and Event Management (EM). SAP BW (Business Information Warehouse) is used to separately store data for variable evaluations. Interfaces for realizing the integration of ECC with SCM, BW or CRM are provided with an appropriate plug-in. The interface between ECC and SCM (APO) is called a Core Interface (CIF).. 4. © 2009 SAP AG. All rights reserved.. 2009.
(13) SCM300. Lesson: Production types of the applications SAP ERP and SAP SCM. Sales orders can be managed using the component SAP CRM, but can be managed in SAP ECC also.. Production Types Depending on the manufacturing process, product complexity, stability of production, and other criteria, a company has various requirements with regard to shop floor control. For this reason, the SAP ERP and SAP SCM applications support a variety of production types.. Figure 4: Production Types (1). 2009. © 2009 SAP AG. All rights reserved.. 5.
(14) Unit 1: Introduction. SCM300. Figure 5: Production Types (2). 6. © 2009 SAP AG. All rights reserved.. 2009.
(15) SCM300. Lesson: Production types of the applications SAP ERP and SAP SCM. Lesson Summary You should now be able to: • you will be able to name the production types that are supported within the SAP Business Suite.. 2009. © 2009 SAP AG. All rights reserved.. 7.
(16) Unit Summary. SCM300. Unit Summary You should now be able to: • you will be able to name the production types that are supported within the SAP Business Suite.. 8. © 2009 SAP AG. All rights reserved.. 2009.
(17) SCM300. Test Your Knowledge. Test Your Knowledge 1.. 2009. Name the production types that are supported within the SAP Business Suite.. © 2009 SAP AG. All rights reserved.. 9.
(18) Test Your Knowledge. SCM300. Answers 1.. Name the production types that are supported within the SAP Business Suite. Answer: • • •. Order-related production with production order Order-related production with process order Repetitive manufacturing:. •. – Period and quantity-oriented production – Not order-related Kanban: –. •. 10. Replenishment-controlled using stock transfer, external procurement, in-house production via self-controlled control cycle Project-oriented production with production lot. © 2009 SAP AG. All rights reserved.. 2009.
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(21) Unit 2 Order-Controlled Production with Production Orders Unit Overview In this unit, you learn about order-controlled production with production orders.. Unit Objectives After completing this unit, you will be able to: • • •. Explain the characteristics of order-based production with production orders Describe the main steps for managing production orders Assess the main functions for managing production orders. Unit Contents Lesson: Order-Controlled Production with Production Orders ............. 12 Lesson: Elements, Functions, and Processing of a Production Order.... 22 Exercise 1: Integration with Planning; Order Creation with Planned Orders, Order Structure..................................................... 47 Exercise 2: Order Release and Order Processing ...................... 61. 2009. © 2009 SAP AG. All rights reserved.. 11.
(22) Unit 2: Order-Controlled Production with Production Orders. SCM300. Lesson: Order-Controlled Production with Production Orders Lesson Overview The following topics are covered in this lesson: • • • •. Application areas of production orders Order-Based Production: Characteristics Cross-application functional process Master data for production orders. Lesson Objectives After completing this lesson, you will be able to: •. Explain the characteristics of order-based production with production orders. Business Example Your company manufactures some kind of order-related product. You belong to the team that is implementing production orders in PPS. To do this, you must implement the whole process chain for in-house production, which will allow your company to organize, control, and execute production for a plant based on the production planning and production control solutions.. 12. © 2009 SAP AG. All rights reserved.. 2009.
(23) SCM300. Lesson: Order-Controlled Production with Production Orders. Application Areas of Production Orders. Figure 6: Application Areas of Production Orders. Production orders are used in a variety of industries and industry sectors. Production orders can be used in a number of production types. These production types are mainly dependent on the product stability, product complexity, and the production procedures used.. 2009. © 2009 SAP AG. All rights reserved.. 13.
(24) Unit 2: Order-Controlled Production with Production Orders. SCM300. Characteristics. Figure 7: Order-Based Production: Characteristics (1). Figure 8: Document Type, Order Category, Order Type. In the SAP system, you use the document type to distinguish between business transactions. Orders are one type of business transactions.. 14. © 2009 SAP AG. All rights reserved.. 2009.
(25) SCM300. Lesson: Order-Controlled Production with Production Orders. The order category is used to distinguish between the various orders that are used in the different applications. The client-specific order category definitions for each application cannot be changed. Within an application, users can define order types for an order category. The order type controls various processes and functions: • • • • •. Number assignment Setting default values User-defined status management User-defined field control (not for production orders in Release ECC 6.0). Control of special functions (activating BDE, QM, LIS and so on). You make all necessary settings in Customizing.. Figure 9: Order-Based Production: Characteristics (2). A number of functions are available for production orders, which allow for complex support of production (see following slides). The course SCM310 covers a selection of the most important functions in detail.. 2009. © 2009 SAP AG. All rights reserved.. 15.
(26) Unit 2: Order-Controlled Production with Production Orders. SCM300. Figure 10: Order-Based Production: Characteristics (3). The PP-PDC (Plant Data Collection) interface is a widespread interface specially designed for production orders, whose contents focus on data exchange between the SAP ECC system and standard plant data collection systems (PDC). Execution Steps (XSteps) are used for the variable description of process instructions and messages in the production order. They form the basis on which data can be exchanged with the process control level (downloading control instructions and uploading process messages) and interactive work instructions generated for the machine operator. SAP ODA (Online Data Access) supports data exchange between SAP ECC and process control systems of different manufacturers in the area of industrial production and is based on the Standard OPC – Open Connectivity in industrial automation: • •. •. This is a manufacturer-independent standard interface for systems in the production area, which is used mainly in process automation. The task of an OPC server is to supply OPC clients (for example, the SAP ECC system) with data from a wide variety of systems installed at the process level. Typical examples include: PLC (Programmable Logic Controller), SCADA (Acronym for Supervisory Control and Data Acquisition), DCS (Distributed Control System), HMI (Human- Machine Interface) You can learn more about OPC under: http://www.opcfoundation.org/. SAP MII (Manufacturing Integration & Intelligence) is an independent SAP software component and enables real-time data integration in Manufacturing Execution Systems (MES) by means of standardized, preconfigured connectors.. 16. © 2009 SAP AG. All rights reserved.. 2009.
(27) SCM300. Lesson: Order-Controlled Production with Production Orders. Cross-Application Functional Process. Figure 11: Cross-Application Functional Process. Production order management is a central part of a complex process chain starting with an independent requirement (planned or customer requirement) and ending with the goods issue of a finished product. Production order management controls the whole process of in-house production of products and is integrated in the functions of capacity requirements planning, costing, and inventory management. Furthermore, there are links and interfaces to Quality Management as well as external systems. The production order management uses the following system elements: ALE, Workflow, Customizing, text processing, factory calendar, classification, communication, and graphics.. 2009. © 2009 SAP AG. All rights reserved.. 17.
(28) Unit 2: Order-Controlled Production with Production Orders. SCM300. Master Data for Production Orders. Figure 12: Master Data for Production Orders. The material to be produced must have the procurement type in-house production (X,E). The BOMs are single-level BOMs. A special selection procedure chooses the valid BOM. The routings are normal routings. A special selection procedure chooses the valid routing. Work centers are assigned to operations in the routing. Production resources/tools are assigned to operations in the routing. Documents (managed in the document management system) can be linked with and displayed in the production order.. 18. © 2009 SAP AG. All rights reserved.. 2009.
(29) SCM300. Lesson: Order-Controlled Production with Production Orders. Demo Scenario: Pump Production in Plant 1000. Figure 13: Demo Scenario: Pump Production in Plant 1000. Demonstration of production with production orders: Pumps and their assemblies (casing, shafts and so on) are manufactured in plant 1000. The final and pre-assembly as well as assembly production take place in the warehouse and partially as make-to-order production. Production is organized on the basis of the workshop principle. The individual parts for assembly production are transferred from the material stock to production by picking or using a pull list. When the assembly is confirmed, the assembly stock receipt is posted directly to the storage location that is assigned to the final assembly production line. Components for final assembly that are not produced at the assembly production lines are transferred from material stock via the pull list. The most important data in the training system is: Material numbers. 2009. R-F1##. Pump. (Make-to-stock and make-to-order production). R-B1##. Casing. (Make-to-stock production). © 2009 SAP AG. All rights reserved.. 19.
(30) Unit 2: Order-Controlled Production with Production Orders. SCM300. Material numbers R-B2##. Warehouse. (Make-to-stock production). R-B3##. Shaft. (Make-to-stock and make-to-order production). R-B4##. Electronics. (Make-to-stock production with production version). Work centers. 20. R-V##. Pre-assembly 1. R-M##. Pre-assembly 2. R-E##. Final assembly 1. R-L##. Paint shop. R-F##. Final assembly 2. R-P##. Check. © 2009 SAP AG. All rights reserved.. 2009.
(31) SCM300. Lesson: Order-Controlled Production with Production Orders. Lesson Summary You should now be able to: • Explain the characteristics of order-based production with production orders. 2009. © 2009 SAP AG. All rights reserved.. 21.
(32) Unit 2: Order-Controlled Production with Production Orders. SCM300. Lesson: Elements, Functions, and Processing of a Production Order Lesson Overview In this lesson, you learn about important elements and functions of a production order as well as the typical way it is processed.. Lesson Objectives After completing this lesson, you will be able to: • •. Describe the main steps for managing production orders Assess the main functions for managing production orders. Business Example Important steps for order-related production are order creation, scheduling, release, printing papers, material withdrawal, execution, confirmation, goods receipt, and settlement. These functions are integrated with other areas in your company, such as, controlling and warehouse management. For this reason, you must take into account the extensive integration relationships of production orders during implementation.. 22. © 2009 SAP AG. All rights reserved.. 2009.
(33) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Production Order Processing and Structure. Figure 14: Production Order Processing. The production order goes through many individual activities. Many of these activities can run automatically or in the background so that manual processing of orders is minimized. A number of settings available in Customizing allow you to successfully perform each step in order processing. (1) These functions can be automated via Customizing. (2) These functions can be executed via background processing. WIP determination, variance calculation, and settlement are generally periodic work for Cost Object Controlling (“COC”), and are usually processed in the background. You can use the quality management (QM) tools during the production process and for the goods receipt. Various interfaces for process integration are available for downloading orders and uploading process messages.. 2009. © 2009 SAP AG. All rights reserved.. 23.
(34) Unit 2: Order-Controlled Production with Production Orders. SCM300. Figure 15: Elements of a Production Order. A production order in SAP ECC has the mapped order structure. A standard sequence of operations may have other (parallel, alternative) operation sequences. You can make a selection from several alternative sequences. The standard sequence must have at least one operation. If necessary, the system creates one automatically. You can choose whether to assign material components, production resources/tools and trigger points to the operation. Suboperations are permitted within an operation. You can link documents of the DMS (drawings, text files, images and so on) to the production order (as of Release 4.6). Execution steps are any process instructions (pressure, temperature, texts…) that can be transferred to a recipient of your choice (control instruction in SAP ECC, process control computer, CNC maschine) using the process integration functions in the form of a control instruction or that can be prepared by this recipient and sent back to the SAP ECC system in the form of process messages (as of Release 6.0 EhP3). Costs are determined at operation level, managed at order header level and a settlement rule is created for the orders for order-related COC only (optional as of release 4.5).. 24. © 2009 SAP AG. All rights reserved.. 2009.
(35) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Order Creation Options. Figure 16: Order Creation Options. Operations, material components and PRTs are usually taken from the routing and the BOM. When opening a production order (and when creating a planned order), the system uses the criteria validity period and lot-size area to determine a suitable production version or direct routing/BOM alternatives for the material. You can use production versions when opening production orders. A production version determines which routing alternative is to be used along with which BOM alternative for production. When creating a production order without a planned order, the routing and BOM are copied directly to the production order. When converting a planned order, the system does not read the BOM again. Instead, the dependent requirements in the planned order are converted into reservations for the production order. In this process, any existing production version is also copied to the production order and the corresponding routing copied. You can create a production order manually any way you want. If not otherwise specified in the routing, the components of the BOM are assigned to the first operation.. 2009. © 2009 SAP AG. All rights reserved.. 25.
(36) Unit 2: Order-Controlled Production with Production Orders. SCM300. Integration with Planning (ECC or SCM (APO)). Figure 17: Integration with Planning (ECC or SCM (APO)). The ERP and SCM components offer two solutions for integrating planning and production: • •. Planning with the functions belonging to the SAP SCM (APO) component Planning with the functions of the SAP ECC component. The production preparation, execution, and control always occurs with the functions of the component ECC, but dependent on the production type. These functions include costing, release, material staging, confirmation, goods movements, and settlement. Other functions (scheduling or the availability check, for example) can be carried out using either of the SAP components. The master data and transaction data (planned orders, production orders, purchase requisitions, purchase orders, stocks and so on) are usually transferred between both SAP components via the interface “Core Interface” (CIF). Specific events lead to the transfer of data from ECC to APO (release, confirmation, goods receipt) and vice versa. Sales orders are usually entered in ECC and then transferred to SCM (APO).. 26. © 2009 SAP AG. All rights reserved.. 2009.
(37) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Planned orders can be generated by material requirements planning in ECC (MRP) or with the following components in SCM: •. Supply Network Planning in SAP 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.. •. Production Planning and Detailed Scheduling in SAP APO (PP/DS) This creates planned orders and purchase requisitions in a defined, short-term period (production horizon) in the production plant.. The SCM210 course covers the Core Interface (CIF) in detail. The SCM220 courses up to SCM250 and SCM360 cover the planning tools in detail.. Order Creation with Planned Orders. Figure 18: Order Creation with Planned Orders. Planned orders are created using material requirements planning (ECC MRP) or using planning in SCM (APO – PP/DS or APO - SNP). The creation of production orders using planned orders is the most important application form in the whole PP application.. 2009. © 2009 SAP AG. All rights reserved.. 27.
(38) Unit 2: Order-Controlled Production with Production Orders. SCM300. The production order data is created automatically in this way. Inspection data is copied from the routing when an inspection lot is generated, but is not written in the production order. The conversion of the planned orders created in production planning into production orders (and the purchase requests into purchase orders) can be carried out by the MRP controllers (purchasers) depending on the execution of production planning both in the SAP ECC system and in SAP SCM (APO).. Order Release Functions. Figure 19: Order Release Functions. The order release is the basis for the processes that follow the production order (printing order documents, material withdrawal, and so on). Production orders are managed using statuses. When an order is released, a status is set accordingly. An availability check can be executed automatically. You can release an individual operation, a whole order or several orders together. A corresponding function is also available for the mass release of operations or orders (see the “Mass Processing” section).. 28. © 2009 SAP AG. All rights reserved.. 2009.
(39) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Detailed Scheduling (Work Center Scheduling). Figure 20: Detailed Scheduling (Work Center Scheduling). Detailed planning (work center processing) can be carried out both in ECC (capacity planning) and in SCM (APO). A prerequisite for all methods of detailed scheduling is long-term or medium-term capacity requirements planning. You can use the order information system to create a list of the operations for each work center. To do this, you must develop a special layout. The courses SCM250 (APO) and SCM360 (ECC) cover capacity requirements planning in detail.. 2009. © 2009 SAP AG. All rights reserved.. 29.
(40) Unit 2: Order-Controlled Production with Production Orders. SCM300. Example: Graphical planning table (APO). Figure 21: Example: Graphical planning table (APO). The screen shows an example of a graphical detailed scheduling planning board in the SAP SCM (APO) system. A planning board like this is also available in the SAP ECC (PP-CRP) system. These planning boards are used for active influencing (capacity leveling measures) in an existing planning situation. The planning boards may vary considerably (they may be customized) in both systems and may contain up to eight horizontal areas. You can use these areas to display the utilization of work centers (capacities), the order due list, the planned operations, the material stock development etc. A second basic display method uses tabular capacity planning tables that enable you to view the utilization of work centers in figures.. 30. © 2009 SAP AG. All rights reserved.. 2009.
(41) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Availability Checks (Material, Capacity, PRT). Figure 22: Availability Checks (Material, Capacity, PRT). Production orders can be checked for material (components), capacity or PRT availability. This can be done manually or automatically, individually or using mass processing. Check instructions control the availability check. Inspection results •. Assigning the confirmed quantity (Partial quantities can be confirmed). • •. Status material shortage, capacity shortage, PRT shortage Missing part record. Depending on how it is controlled, the check is performed in the SAP ECC or SCM (APO) component.. 2009. © 2009 SAP AG. All rights reserved.. 31.
(42) Unit 2: Order-Controlled Production with Production Orders. SCM300. Shop Floor Papers (Standard List Types). Figure 23: Shop Floor Papers (Standard List Types). The standard system provides various lists. These lists are compiled by list-specific reports. The user can generate additional lists. For each order, a maximum of 20 lists may be called. You use the document distribution to plot document originals.. 32. © 2009 SAP AG. All rights reserved.. 2009.
(43) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Material Staging Process. Figure 24: Material Staging Process. The basis for material withdrawal for production orders may be material withdrawal slips, pull lists, pick lists, work instructions, weighing systems (basic execution steps) connected using the interface PI-PCS or similar documents or techniques. To organize the material staging, the SAP ECC and SAP SCM systems provide the following different procedures that depend on the type of inventory management and warehousing: 1. 2. 3.. 2009. Warehouse management with the MM-IM (Inventory Management) component Replenishment control with the KANBAN component Storage bin management and replenishment control with a warehouse management system based on the component LE-WM (SAP ECC) or EWM (SAP SCM).. © 2009 SAP AG. All rights reserved.. 33.
(44) Unit 2: Order-Controlled Production with Production Orders. SCM300. For the material staging from a warehouse management system, there are three options for the production order. These options are described here: •. •. Pick parts are provided for the production order in exactly the same quantity as the requirements quantity. The staging of these parts for the production order may occur in a physical storage bin or a dynamic storage bin (production order). Typical examples are high value parts such as waves and casings. Crate parts are ordered manually when a crate is almost empty. Typical examples are small parts in containers such as screws, nails, ..... •. Release order parts are ordered manually. The required quantity is calculated using the target quantities of the components in the selected released orders. Typical examples are laminates, paints, ... Production Order: Goods Issue Posting. Figure 25: Production Order: Goods Issue Posting. The goods issue posting (GI) is executed for consumption of a material component for a production order.. 34. © 2009 SAP AG. All rights reserved.. 2009.
(45) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. The following functions are executed when a goods receipt is posted: • • • • • • • • •. Storage location-related update of stock and consumption fields Reduction of reservations (for planned withdrawal) Determination of actual costs (evaluation) and update of order Generation of material documents, accounting documents and cost accounting documents The material document describes the goods movement from the materials management (stock) point of view. The accounting document describes the goods movement from the financial accounting point of view. The cost accounting documents are used for various cost analysis purposes. When you display the material document, you can branch to the other documents. You can print a goods issue document.. The GI posting is controlled using a movement type (261), to which each posting refers. This can take place manually or automatically.. Confirmations. Figure 26: Confirmations – Overview. 2009. © 2009 SAP AG. All rights reserved.. 35.
(46) Unit 2: Order-Controlled Production with Production Orders. SCM300. Confirmations are an important basis for entering internal activities performed for the order, for the progress check and subsequent capacity requirements planning. For this reason, exact real-time confirmations are of particular importance. A confirmation causes various additional functions to be executed (see above). Confirmations are always executed in the SAP ECC component, but can be implemented with various technical procedures. The standard system provides a range of online transactions in SAP ECC (see the next slide). Users of the browser-based Enterprise Portal can carry out confirmations as part of the role of a production scheduler. Confirmations from PDC systems are possible using the PP-PDC interface (see previous unit). Confirmations can be automatically generated and processed using automatic process messages which, in turn, are generated from work instructions, using the PI-PCS interface, or using SAP ODA (see previous unit). Confirmations can be generated and updated via an Mii server (see previous unit). As of Release 4.6, custom-programmed confirmation interfaces and external systems can be linked to the SAP ECC system, using and adapting the following BAPIs: • •. 36. BAPI_PRODORDCONF_PDC_UPLOAD_TE (time-event confirmation) BAPI_PRODORDCONF_PDC_UPLOAD_TT (time-ticket confirmation). © 2009 SAP AG. All rights reserved.. 2009.
(47) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Figure 27: Confirmations. There are various procedures for confirmations in SAP ECC. Each procedure implements different requirements that a company may have. Depending on the application, one or more procedure may be used. The procedures must be selected to suit the methods of organization within your company and the allowed workload. For the most part, the two main types are operation-related and order-related confirmations. Order confirmation is a confirmation of the entire order at order header level. An operation confirmation allows you to confirm an order step by step. For this type of confirmation, there are various procedures available. You can carry out a confirmation for an order only if no confirmations have already been entered for the operations. Each confirmation is entered with a status (partial confirmation, final confirmation, automatic final confirmation).. 2009. © 2009 SAP AG. All rights reserved.. 37.
(48) Unit 2: Order-Controlled Production with Production Orders. SCM300. Effects of a Confirmation. Figure 28: Effects of a Confirmation. Once an order has been confirmed, follow-on functions are performed. The confirmed quantity, the status RÜCK and actual costs are written to the production order. When an operation is confirmed, an automatic goods issue is posted on the basis of the quantity that has been assigned the material components (backflush). These material components must be prepared for backflush posting and also be provided for use at the work center. When you confirm the last operation that must be confirmed (or for the operation where this posting is defined in the control key), an automatic goods receipt is posted. Capacity reduction is carried out either in proportion to the quantity or activity. If a scrap or rework quantity is confirmed, a quality notification can be generated automatically (as of ECC 6.0 EhP3).. 38. © 2009 SAP AG. All rights reserved.. 2009.
(49) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Process Integration. Figure 29: Process integration. The process integration forms the interface between PP-SFC and the systems that are involved in process control (process control computers, process control systems, CNC control and so on.). The flexible structure of process integration enables the connection of fully automated, partially automated and manually operated lines. Process integration consists of the following functions: • •. Bidirectional communication with standard plant data collection (PDC) systems via the interface Plant Data Collection (PP-PDC). Communication with the process control level using the PI-PCS interface or using work instructions (see also Unit 4 Process Orders): –. –. –. 2009. Generating and sending control instructions with variable process instructions from released production orders. These process instructions provide a detailed definition of the process steps to be executed and the actual data to be confirmed (via process messages). Formatting the control instructions in natural language in the form of work instructions and their manual processing by the machine operator on screen. Sending the control instructions to process control computers using the PI-PCS interface and processing them automatically.. © 2009 SAP AG. All rights reserved.. 39.
(50) Unit 2: Order-Controlled Production with Production Orders. SCM300. Receiving, checking and sending manually or automatically entered process messages with the actual data of the production process from the work instructions or the process control system. The data is transferred from the external system using the PI-PCS interface too. Reading and writing data points and events using the function SAP OPC Data Access (SAP ODA) by means of the OPC server of the ECC system (reading and writing using work instructions or by means of the function Automatically Create Process Messages). Further process integration options include using the application Mii and the RFID.. Production Order: Goods receipt posting. Figure 30: Production Order: Goods receipt posting. The goods receipt posting (GR) is executed for the stock receipt of a product produced using a production order.. 40. © 2009 SAP AG. All rights reserved.. 2009.
(51) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. The following functions are executed when a goods receipt is posted: • • • • • • • • • •. Generation of material documents, accounting documents and cost accounting documents The material document describes the goods movement from the materials management (stock) point of view. The accounting document describes the goods movement from the financial accounting point of view. The cost accounting documents are used for various cost analysis purposes. When you display the material document, you can branch to the other documents. You can print a goods receipt document. Update of the delivered quantity in an order Evaluation of the receipt Credit to order Update of plant activity. The GR posting is controlled using a movement type (101), to which each posting refers. This can take place manually or automatically.. Debiting and Crediting. Figure 31: Cost Debit/Credit (Order-Related COC). 2009. © 2009 SAP AG. All rights reserved.. 41.
(52) Unit 2: Order-Controlled Production with Production Orders. SCM300. The manner in which a production order is credited and debited depends on the variant of cost object controlling (COC) selected in Controlling. You can perform this as follows: • •. order-related product-related. Order settlement credits the order. Settlement is usually periodic. It is controlled using a settlement profile. It makes sense to use the order-related COC if the following conditions exist: • • • • • •. Flexible production environment Flexible product range Cost management of individual production lots If cost controlling is required for each order High setup costs Manufacture of co-products. For in-house production of materials, it is generally best to use standard price control. For more information on cost object controlling, see course AC520.. Figure 32: Cost Debit/Credit (Product-Related Cost Object Controlling). Settlement is period-oriented based on the costs of the product cost collector.. 42. © 2009 SAP AG. All rights reserved.. 2009.
(53) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. The order settlement for the individual production order does not apply here. In this case, the production order has no costs and no settlement rule. It makes sense to use the product-related COC if the following conditions exist: • • •. Make-to-stock production Repetitive, mass production Product cost by sales order only in the profitability analysis. Figure 33: Order-Based Production: Characteristics (4). 2009. © 2009 SAP AG. All rights reserved.. 43.
(54) Unit 2: Order-Controlled Production with Production Orders. SCM300. Figure 34: Order-Based Production: Characteristics (5). Mass Processing (HVOM). Figure 35: Mass Processing (HVOM). 44. © 2009 SAP AG. All rights reserved.. 2009.
(55) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Collective Orders. Figure 36: Collective Orders. Collective orders are the only option for multi-level management of production orders and for the complete integration in all modules (SD, MM and so on) of the SAP ECC system. A separate subordinate order is created for each bill of material component whose material master has special procurement key 52 (special procurement type direct production). Individual orders can be added or deleted. You can make every component of an order into an order (whether it is with or without special procurement key “52”). Other useful special procurement types, for example, “production in another plant”, can be combined with direct production (collective order).. 2009. © 2009 SAP AG. All rights reserved.. 45.
(56) Unit 2: Order-Controlled Production with Production Orders. SCM300. Information Systems for Order Management. Figure 37: Information Systems for Order Management. There are flexible evaluation options and several information systems for production orders. You will find most of these evaluation options under: ECC → Logistics → Production → Shop Floor Control → Information System. They differ in the way they use the order database (directly or indirectly) as well as in the results they can show. Systems marked with (1) are layout-controlled (profile-controlled up to Release 5.0). You set layouts in the respective application. You can use the Enterprise Portal for the role of a production scheduler to process and track production orders and other objects (inspection lots, quality notifications, malfunction reports, and maintenance orders). In addition to the above-mentioned evaluation options, there are • • • • •. 46. Capacity evaluations Event Manager (SCM) Alert Monitor (APO) Batch where-used list Evaluation of digital signatures and other lists.. © 2009 SAP AG. All rights reserved.. 2009.
(57) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Exercise 1: Integration with Planning; Order Creation with Planned Orders, Order Structure Exercise Objectives After completing this exercise, you will be able to: • Perform the requirements planning • Convert planned orders to production orders • Use the structure and interface of the production order. Business Example Your company consistently uses material requirements planning based on SAP ECC or SAP SCM (APO). As the production manager, MRP controller or production scheduler, you therefore create a large number of production orders based on planned orders generated by the automatic material requirements planning run. List of abbreviations for menu paths: ECC – System SAP ECC SCM – System SAP SCM LO – Logistics PP – Production SFC – Shop Floor Control MM – Materials Management SD – Sales and Distribution Exercise Data. 2009. © 2009 SAP AG. All rights reserved.. 47.
(58) Unit 2: Order-Controlled Production with Production Orders. SCM300. Task 1: You generate planned orders based on planned independent requirements. Convert these planned orders to production orders, then get familiar with the order structure. 1.. Check the stock/requirement situation for the following materials in plant 1000. R-F1##. Finished products. R-B3##. Assembly. Write down the current available quantity quantity for MRP element Stock: R-F1## ______________________ R-B3## ______________________ 2.. Enter a sales order in Sales and Distribution for product R-F1## with the order quantity 1 piece. Use the following requirements parameter: Order type. OR (standard order). Sales organization. 1000. Distribution channel. 10 (End customer sales). Division. 00 (Division-wide). Sales office. 1000 (Frankfurt). Sold-to party. 1000 (Becker Company, Berlin). Ship-to party. 1000 (Becker Company, Berlin). PO number. GR##_001. Requested delivery date. Current date + 1 month. Hint: If the system suggests a different delivery date, confirm this by choosing Enter. Save the sales order. Write down the order number and item: Order number ________________ Item _________ 3.. Perform multilevel single-item MRP for the product R-F1## in plant 1000. Continued on next page. 48. © 2009 SAP AG. All rights reserved.. 2009.
(59) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Use the following data: Field. Entry. Processing Key. NETCH (Net change for the total horizon). Create purchase requisition. 3 (Planned Orders). Delivery schedules. 1 (No schedule lines). Create MRP list. 1 (MRP list). Planning mode. 1 (Adapt planning data (normal mode)). Scheduling. 2 (lead time scheduling). Caution: Do not select any checkboxes in the Process control parameters screen area. 4.. Check the stock/requirements situation again for the materials R-F1## and R-B3##. What do you notice?. Task 2: Familiarize yourself with the structure of planned orders and convert the planned orders to production orders (individual and collective conversion). 1.. Examine the details for a planned order of material R-F1## by displaying the order from the stock/requirements list. Write down the number of this planned order: ____________________________. 2.. Choose the Header tab page and make a note of the planned dates. Planned start date:. ________________. Planned finish date:. ________________. Planned opening date:. ________________. Availability date:. ________________. Does the planned order have a production version? Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 49.
(60) Unit 2: Order-Controlled Production with Production Orders. SCM300. 3.. Choose the Assignment tab page. Who is the production scheduler responsible?. 4.. Display the material components (dependent requirements) of the planned order.. 5.. Convert the planned order with the total quantity to a production order of the order type PP01. To do this, follow the menu path in Production Control. Write down the number of the production order created: ____________________________. 6.. Is the converted planned order still in the stock/requirements list? Hint: Planned orders can also be converted to production orders from the stock/requirements list. To do this, select the planned order with or by double-clicking and then → ProdOrd.. 7.. Check the Assignment tab page header in the production order generated. Do you still see the reference to the planned order?. 8.. Convert several planned orders to production orders at the same time. Use collective conversion to do this. Select the planned orders to be converted with the following parameters: Planning plant:. 1000. MRP controller. 0##. Material. R-F1##. Order type. PP01. Limit the selection date (to one month before or one month after the current date). Write down the numbers of the planned orders you converted: Planned order number. Production order number. ____________. ____________. ____________. ____________. ____________. ____________. Continued on next page. 50. © 2009 SAP AG. All rights reserved.. 2009.
(61) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Task 3: In one of the production orders you have generated, look at the individual data segments, screens, and data fields in the following sequence. Note down any questions you may have on the meaning of the data fields and ask your instructor. 1.. Order header screens Choose the appropriate tab for the following screens: •. General. •. Assignment. •. Goods receipt. •. Control. •. Dates/Quantities. •. Master Data. •. Long text. Also notice the settlement rule of the order. 2.. Overview of operation sequences. 3.. Operation sequence details. 4.. Operation Overview. 5.. Screens of the Operation Select the operation “0010”.. 6.. Material components – Overview. 7.. Screens of the material component Select the component “0010”. Display the General Data and the Long Text .. 8.. Production resource/tool overview for operation “0010”. 9.. Screens of the PRT Select the PRT “0010”.. 10. Document overview 11. Display the document info record. Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 51.
(62) Unit 2: Order-Controlled Production with Production Orders. SCM300. 12. Display the original document. View both originals from the order's document overview. 13. Display the costs. 52. Itemization. (costs). Analysis. (cost elements). Cost component split. (cost components). © 2009 SAP AG. All rights reserved.. 2009.
(63) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Solution 1: Integration with Planning; Order Creation with Planned Orders, Order Structure Task 1: You generate planned orders based on planned independent requirements. Convert these planned orders to production orders, then get familiar with the order structure. 1.. Check the stock/requirement situation for the following materials in plant 1000. R-F1##. Finished products. R-B3##. Assembly. Write down the current available quantity quantity for MRP element Stock: R-F1## ______________________ R-B3## ______________________ 2.. Enter a sales order in Sales and Distribution for product R-F1## with the order quantity 1 piece. Use the following requirements parameter: Order type. OR (standard order). Sales organization. 1000. Distribution channel. 10 (End customer sales). Division. 00 (Division-wide). Sales office. 1000 (Frankfurt). Sold-to party. 1000 (Becker Company, Berlin). Ship-to party. 1000 (Becker Company, Berlin). PO number. GR##_001. Requested delivery date. Current date + 1 month. Hint: If the system suggests a different delivery date, confirm this by choosing Enter. Save the sales order. Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 53.
(64) Unit 2: Order-Controlled Production with Production Orders. SCM300. Write down the order number and item: Order number ________________ Item _________. 3.. a). Menu path: ECC→ Logistics → Sales and Distribution → Sales → Order → Create. b). The order number appears below in the status bar, once you have saved.. Perform multilevel single-item MRP for the product R-F1## in plant 1000. Use the following data: Field. Entry. Processing Key. NETCH (Net change for the total horizon). Create purchase requisition. 3 (Planned Orders). Delivery schedules. 1 (No schedule lines). Create MRP list. 1 (MRP list). Planning mode. 1 (Adapt planning data (normal mode)). Scheduling. 2 (lead time scheduling). Caution: Do not select any checkboxes in the Process control parameters screen area.. 4.. a). Menu path: ECC → Logistics → Production → MRP → Planning → Multilevel Single-Item Planning. b). To run the requirements planning, select Enter and confirm the entry parameters by selecting Enter again.. Check the stock/requirements situation again for the materials R-F1## and R-B3##. What do you notice? Answer: Planned orders have been generated.. Task 2: Familiarize yourself with the structure of planned orders and convert the planned orders to production orders (individual and collective conversion). 1.. Examine the details for a planned order of material R-F1## by displaying the order from the stock/requirements list. Write down the number of this planned order:. Continued on next page. 54. © 2009 SAP AG. All rights reserved.. 2009.
(65) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. ____________________________ a) 2.. Choose Details of Element, or double-click on the order number, to call the planned order and select Change Element.. Choose the Header tab page and make a note of the planned dates. Planned start date:. ________________. Planned finish date:. ________________. Planned opening date:. ________________. Availability date:. ________________. Does the planned order have a production version? a) 3.. Choose the Assignment tab page. Who is the production scheduler responsible? a). 4.. Production scheduler 0##. Display the material components (dependent requirements) of the planned order. a). 5.. No, the planned order has no production version.. Choose. Components (quick-info Component Overview).. Convert the planned order with the total quantity to a production order of the order type PP01. To do this, follow the menu path in Production Control. Write down the number of the production order created: ____________________________. 6.. a). Menu path: ECC → Logistics → Production → Shop Floor Control → Order → Create → From Planned Order. b). Enter the planned order number and press Enter.. c). Save the production order.. Is the converted planned order still in the stock/requirements list? Hint: Planned orders can also be converted to production orders from the stock/requirements list. To do this, select the planned order with or by double-clicking and then → ProdOrd. a). 7.. No, this planned order no longer exists in the stock/requirements list.. Check the Assignment tab page header in the production order generated. Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 55.
(66) Unit 2: Order-Controlled Production with Production Orders. SCM300. Do you still see the reference to the planned order?. 8.. a). Menu path: ECC→ Logistics → Production → Shop Floor Control → Order → Display. b). The planned order number is still visible.. Convert several planned orders to production orders at the same time. Use collective conversion to do this. Select the planned orders to be converted with the following parameters: Planning plant:. 1000. MRP controller. 0##. Material. R-F1##. Order type. PP01. Limit the selection date (to one month before or one month after the current date). Write down the numbers of the planned orders you converted: Planned order number. Production order number. ____________. ____________. ____________. ____________. ____________. ____________. a). Menu path: ECC → Logistics → Production → Shop Floor Control → Order → Create → Collective Conversion of Planned Orders. b). Enter the selection parameters including the planned opening date.. c). Select Execute.. d). In the list screen of the planned orders, select the orders that are to be Convert pushbutton (short info Planned converted and select the Order list → Convert). Hint: The. Convert button is on the bottom left.. Continued on next page. 56. © 2009 SAP AG. All rights reserved.. 2009.
(67) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Task 3: In one of the production orders you have generated, look at the individual data segments, screens, and data fields in the following sequence. Note down any questions you may have on the meaning of the data fields and ask your instructor. 1.. Order header screens Choose the appropriate tab for the following screens: •. General. •. Assignment. •. Goods receipt. •. Control. •. Dates/Quantities. •. Master Data. •. Long text. Also notice the settlement rule of the order. a). Menu path: ECC → Logistics → Production → Shop Floor Control → Order → Change Hint: If you are on a detail screen of the production order, choose (menu path Goto → Header).. b) 2.. Overview of operation sequences a). 3.. 4.. To call the settlement rule, choose Header → Settlement rule. Choose. (menu path: Goto → Overviews → Sequence overview).. Operation sequence details a). Select the sequence. b). Choose. (menu path: Sequence → Details).. Operation Overview a). Choose. (menu path: Goto → Overviews → Operations). Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 57.
(68) Unit 2: Order-Controlled Production with Production Orders. 5.. SCM300. Screens of the Operation Select the operation “0010”.. 6.. a). In the operation overview, select the operation for item 0010.. b). Choose. c). Choose the appropriate tabs for the individual screens.. Material components – Overview a). 7.. (Operation → Operation Details).. Choose. (menu path: Goto → Overviews → Components).. Screens of the material component Select the component “0010”. Display the General Data and the Long Text .. 8.. 9.. a). Select the component for item 0010.. b). Choose. c). Choose the corresponding tab pages for the General Data and Long Text screens.. (menu path: Component → Component Detail).. Production resource/tool overview for operation “0010” a). Choose Goto → Overviews → Operations.. b). Select the operation for item 0010.. c). In the lower toolbar, select. PRT (short info Operation PRT's).. Screens of the PRT Select the PRT “0010”. a). Select the PRT for item 0010.. b). (menu path: Production Resources/Tools → Details Choose Production Resources/Tools).. c). Choose the corresponding tab pages for the General, Quantities, and Dates screens.. 10. Document overview a). Choose. (menu path: Goto → Overviews → Documents).. 11. Display the document info record. a). Select the first document.. b). Choose. c). Choose the appropriate tabs for the individual screens.. (menu path: Document → Display document info record).. 12. Display the original document. Continued on next page. 58. © 2009 SAP AG. All rights reserved.. 2009.
(69) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. View both originals from the order's document overview. a). Select the first document.. b). Choose. c). Select one of the bitmap files.. d). Select Continue.. e). Repeat steps c and d for the other bitmap file.. (menu path: Document → Display original document).. 13. Display the costs Itemization. (costs). Analysis. (cost elements). Cost component split. (cost components). a). 2009. From the header of the production order, choose Goto → Costs → Itemization or Analysis or Cost comp. structure.. © 2009 SAP AG. All rights reserved.. 59.
(70) Unit 2: Order-Controlled Production with Production Orders. 60. © 2009 SAP AG. All rights reserved.. SCM300. 2009.
(71) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Exercise 2: Order Release and Order Processing Exercise Objectives After completing this exercise, you will be able to: • Perform the order release • Print shop floor papers • Perform the material staging • Perform the material withdrawal • Perform an operation confirmation • Post the goods receipt (to stock) • Check the order progress in the order information system. Business Example Your company uses production orders to control production. As the production manager or production supervisor, you are responsible for shop floor control and, as an employee in production, you work based on production orders. In this exercise you will perform the whole management process for a production order. It starts with the release of production orders and ends with the goods receipt of the material produced. You will use the order information system to control this whole process.. Task 1: Perform collective production order release for all orders with your production scheduler number. Hint: Note the default release period. 1.. Choose the Selection tab and enter the following parameters: List. Order Headers. Layout. Standard layout. Production plant. 1000. Order type. PP01. Production supervisor. 0##. System status. REL Released and Exclude. Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 61.
(72) Unit 2: Order-Controlled Production with Production Orders. 2.. SCM300. Choose the Mass Processing - Release tab page and make the following settings: Field. Settings. Function. Release. Execute function. Execute function immediately. Release control order. Order release. 3.. Select all production orders and start the release (mass processing).. 4.. Check the release log for any errors.. 5.. Check the status changes in one of the production orders. What is the new status?. Task 2: Print all the shop floor papers for all the released orders of your production scheduler number. Use mass processing to print the production orders. 1.. 2.. Choose the Selection tab and enter the following parameters: List. Order Headers. Layout. Standard layout. Production plant. 1000. Order type. PP01. Production supervisor. 0##. Selection profile status. PP00008. Choose the Mass Processing - Printing of Shop Floor Papers tab page and make the following settings:. Continued on next page. 62. © 2009 SAP AG. All rights reserved.. 2009.
(73) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Field. Settings. Function. Printing of shop floor papers. Execute function. Execute function immediately. Print mode. Original print. 3.. Select all production orders and start printing (mass processing).. 4.. Check the print log for any errors.. 5.. Look at the printing results.. 6.. Check the status changes in one of the production orders. What is the new status?. Task 3: Perform material staging and the goods issue posting for all the released orders of your production scheduler number. Create a pick list for staging the material components of the order in stock. 1.. 2.. Select the orders with the following parameters: Profiles. 000002 (standard pick profile). Plant. 1000. Order type. PP01. Production supervisor. 0##. Use the Pick function to post the goods issues and save the result. Hint: If there is not enough stock to withdraw a material, use transaction MB1C, movement type '561', to perform an other goods receipt for the material. Post a sufficient quantity. Hint: To display errors in picking, choose Environment → Errors. Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 63.
(74) Unit 2: Order-Controlled Production with Production Orders. SCM300. 3.. Look at the update in an order (documented goods movements, withdrawal quantities, actual costs).. 4.. Check the status change in the production order. What is the new status?. Task 4: Choose one of the orders processed so far for material R-F1## to perform confirmations. Order number: _________________________ 1.. Perform a final confirmation (quantity and time) for operation '0070'. Use the operation-related confirmation for the “progress confirmation”. Hint: This type of operation-related confirmation confirms all operations automatically and by quantity.. 2.. Display the confirmations performed for the order.. 3.. Look at the update (actual quantities, status, costs) in the order (order header, operations).. 4.. Check the material stock for material 'R-F1##'. Material stock: _____________________. Continued on next page. 64. © 2009 SAP AG. All rights reserved.. 2009.
(75) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. 5.. Was the stock receipt posted automatically?. 6.. Is the order still in the stock/requirements list?. 7.. Check the status change in the production order. What is the new status?. Task 5: Post a goods receipt for the whole order quantity of a different production order for material R-F1##. 1.. Go to the detail screen for the posting and check the data. Hint: The movement type for the goods receipt from production can be found in the menu.. 2.. Generate the overview for the goods receipt posting.. 3.. Save the goods receipt and note the material document number. ____________________. Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 65.
(76) Unit 2: Order-Controlled Production with Production Orders. 4.. SCM300. Check the update of the delivered quantity in the order. What is the new status?. Task 6: Use the order information system to check the order progress of all the production orders for your production scheduler number. 1.. Select the orders with the following parameters: List. Order Headers. Layout. /SCM310_001. Production plant. 1000. Order type. PP01. Production Scheduler. 0##. 2.. Are the orders that have already been delivered displayed?. 3.. Repeat the order information system call with the following additional lists in the selection screen. All other selection parameters remain the same. List. Documented Goods Movements. List. Operations. List. Object Overview Hint: In the object overview, the system hides the layout for technical reasons and displays profile 00000000001X. In the list generated, you can expand individual objects (operations, components) of an order.. 66. © 2009 SAP AG. All rights reserved.. 2009.
(77) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. Solution 2: Order Release and Order Processing Task 1: Perform collective production order release for all orders with your production scheduler number. Hint: Note the default release period. 1.. Choose the Selection tab and enter the following parameters: List. Order Headers. Layout. Standard layout. Production plant. 1000. Order type. PP01. Production supervisor. 0##. System status. REL Released and Exclude. a) 2.. Choose the Mass Processing - Release tab page and make the following settings: Field. Settings. Function. Release. Execute function. Execute function immediately. Release control order. Order release. a) 3.. Menu path: ECC → Logistics → Production → Shop Floor Control → Control → Collective Release.. No solution required.. Select all production orders and start the release (mass processing). a). To begin the selection, choose. b). Select all orders in the detail list.. c). To begin the release, choose Execute).. . (menu path: Mass Processing →. Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 67.
(78) Unit 2: Order-Controlled Production with Production Orders. 4.. Check the release log for any errors. a). 5.. SCM300. Choose Order (Menu path: Mass Processing → Log of Last MP).. Check the status changes in one of the production orders. What is the new status? Answer: REL (released). Task 2: Print all the shop floor papers for all the released orders of your production scheduler number. Use mass processing to print the production orders. 1.. Choose the Selection tab and enter the following parameters: List. Order Headers. Layout. Standard layout. Production plant. 1000. Order type. PP01. Production supervisor. 0##. Selection profile status. PP00008. a) 2.. Menu path: ECC → Logistics → Production → Shop Floor Control → Control → Print.. Choose the Mass Processing - Printing of Shop Floor Papers tab page and make the following settings: Field. Settings. Function. Printing of shop floor papers. Execute function. Execute function immediately. Print mode. Original print. a) Hint: The original print print function prints all the released operations of the order that have not been printed. Continued on next page. 68. © 2009 SAP AG. All rights reserved.. 2009.
(79) SCM300. Lesson: Elements, Functions, and Processing of a Production Order. 3.. 4.. Select all production orders and start printing (mass processing). a). To begin the selection, choose. b). Select all orders.. c). To start printing, choose. 6.. (menu path: Mass Processing → Execute).. Check the print log for any errors. a). 5.. .. Choose order (menu path: Mass Processing → Log of Last MP).. Look at the printing results. a). Menu path: ECC → System → Services → Output Control or transaction SP01.. b). Use your user name and the current date to select.. c). Choose Selection → Execute.. d). Select a spool order.. e). Select. Display Content.. Check the status changes in one of the production orders. What is the new status? Answer: PRT (printed). Task 3: Perform material staging and the goods issue posting for all the released orders of your production scheduler number. Create a pick list for staging the material components of the order in stock. 1.. Select the orders with the following parameters: Profiles. 000002 (standard pick profile). Plant. 1000. Order type. PP01. Production supervisor. 0##. a). Menu path: ECC → Logistics → Production → Shop Floor Control → Goods Movements → Material Staging → Pick.. b). Enter the selection parameters.. c). Select. Execute.. Continued on next page. 2009. © 2009 SAP AG. All rights reserved.. 69.
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