SAP Supply Chain Management is one of the key modules in SAP ERP and controls This tutorial is meant for Project leaders, project team members, SAP. SAPSCM (SAP SCM Solution Overview) SAP ECC Enhancement Package 6 Basic Processes & Foundation. Exam.: Sample Questions.: PDF Link. Shaun Snapp Discover SAP SCM ® Bonn Boston caite.info 3 11/ 3/09 PM Recovering Failed SAP SCM Implementations.
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SCM Business Processes in. Manufacturing (SAP ERP).. COURSE OUTLINE. Course Version: Course Duration: 3 Day(s). SAPSCM - mySAP Supply Chain Management caite.info SAPSCM - SAP Planning and Detailed caite.info SCM - Production caite.info SAP AG. SCM Appendix: mySAP Business Suite and Production. Contents: mySAP Business Suite: Solutions, Key Areas, Components Key Areas in the.
When an order is released. Non-valuated project stock means that quantity flows and value flows are separated. Course Overview Contents: Post a goods receipt for the whole order quantity of a different production order for material R-F1. It makes sense to use product-related COC for the following: After you have released the order and created the control recipe. Staging is performed for line T-L3 in plant for all requirements that are received until Tuesday in two weeks.
Whether the client knew the optimizer was not being used is unknown. This is more common than reading press releases and industry periodicals in the area would make you think. Implementing and maintaining optimization methods requires much effort and long-term investment. Secondly, optimization requires a great deal of discipline and knowledge on the part of the implement- ing company.
Many companies want the benefit of advanced plan- ning but are not culturally, financially, or skills-wise prepared to make the sacrifices required to get the outcomes they desire. More often than not, companies want simple solutions that deliver value quickly. And this is partly because the software has historically been designed to be more com- plex than is necessary Figure 1.
As with other planning software, the best successes typically come from companies that are already good at planning. Part of this is content knowledge of planning, but another component is open mindedness to new approaches.
Focused on Transaction processing systems such as SAP improvement ERP are a necessity, but a business can still run without a planning system. Some applications request the estimation of a cost of a lost sale, so those successful with SAP SCM are effective at asking these questions and getting answers. However, more generally, SAP SCM is most beneficial to companies that are dedicated to improving their planning processes and that already have good planning processes to begin with.
Being effective at planning helps the company know how to design the system and also allows the company to better le- verage what it ends up implementing. Cross Application Components As mentioned earlier, this book is broken into a format of one chap- ter per application.
However, there are some important concepts and components that cut across the applications, so even though all of the components will be addressed in the same form in individual chap- ters, they may also be covered in other chapters. The product master contains the information and attributes that relate to the product across all locations.
Data elements such as the product number, the material group, and the gross weight and volume are all attributes of the product master.
The product mas- ter is set up once per product. The location master deals with the attributes of the location. The product location master is essentially the product master with added fields and added tabs to hold these fields that modify the product per location. This not only holds true for safety stock but also for many other attributes that only come into play at the product location master. Planning Areas and Planning Object Structures Planning areas are Planning areas and planning object structures are important cross ap- containers for plication items.
They have a central administration that al- lows the areas and structures to be copied, maintained, and deleted. A planning area is a container for key figures. Planning areas feed an interface object called a planning book, which is a spreadsheet view with a number of aggregation and macro capabilities.
At the most basic level, key figures are the numerical values in the spreadsheet. Planning Object Structure Just as a planning area is a container for key figures, a planning object structure POS is a container for characteristics. The combination of characteristics is called characteristic value combinations CVCs.
The POS stores every unique combination of CVCs, which is then used to help control disaggregation when data is manipulated at summary levels. In the previous analogy, we stated that key figures are the nu- merical values in the planning book spreadsheet. Characteristics are like the textural column and row headings, with the time characteris- tic on the horizontal axis, and the product characteristics on the verti- cal axis.
A Planning versions model with the same supply network can have slight alterations in are variations of the planning models terms of control fields on, say, the product location master, making the version create different planning results than a different version of the same model that has the original product location master set- tings.
Multiple versions can be kept over time and run to see how the results change. Because only the active version planning results are communicated back to SAP ERP, multiple versions can be run in per- petuity along with a live active version, without ever impacting the active version. If the changes are deemed desirable, then the settings from the inactive version can be migrated over to the active version. This allows the person performing the configuration to make wholesale changes in the mas- ter data; however, this transaction should not be used on the active version.
Instead, by using the simulation planning version and then mass maintenance to make changes, the changes can be fully tested before mass maintenance to make the tested changes on the active version.
Planning books consist of the fol- lowing areas: Planning books allow you to com- bine characteristics and key figures in a flexible way for presentation to the planners. Creating the planning books is a significant part of the implementa- tion because there are many different combinations of planning books that can be created. All planned costs. WIP is created for the orders as it is for collective stock and does not need to be calculated by results analysis as it needs to be for non-valuated stock.
In the example. Only the goods receipt for the purchase order creates an FI document that is assigned to the WBS element. WIP stocks must be created by results analysis and its settlement.
Non-valuated project stock means that quantity flows and value flows are separated. In networks or production orders.
Goods issues. Non-Valuated Project Stock: Incomplete costs at orders! No FI documents!! The material movements are usually non-valuated. Procurement for these materials for example. Collective Stock: Every quantity posting for example.
Only the reservation and the later goods issue of assembly T-POP to the network is displayed. The production order for producing T-POP and its costs are not shown in the project information system. Systems marked with 1 are profile-controlled.
You set up the profile in Customizing for the relevant application shop floor control. Information Systems Basis 1 Order information system Multi-level order overviews for projects and sales orders Orders 1 1 Project and order structure Missing parts. They differ in the way they use the order database directly or indirectly as well as in their results. Using production lots in make-to-order production enables the planning and pre-production of individual parts.
Summary Project-oriented production is a form of production planning and shop floor control that has particular advantages for make-to-order production with long lead times. Its main characteristic is the use of production lots WBS elements as account assignment objects for production planning. At the conclusion of this unit, you will be able to: Explain the characteristics of order-controlled production with process orders Describe the individual steps in process order management Describe the concept of process management and use a PI sheet to execute a process order Explain the special functions for process order management in the pharmaceutical area.
Your company is a process manufacturing company. You produce order-related products. You are on the project team for implementing shop floor control functions based on process orders. Important steps in process order management are order creation, batch determination, scheduling, availability check, release, transfer of control recipes to process control, material withdrawal, confirmations, material delivery, and settlement.
To link the process control level with process control systems and PI sheets, you must set up the process management functions. For the production of pharmaceutical products, you require the following functions: Production Production according according to to customer's customer's reqmts reqmts. Process orders are used in different areas of the process manufacturing industry.
Process orders can be used for various production procedures and identified, for example, according to the criteria product complexity and product stability.
Process Order-Controlled Production: Characteristics 1 Order-Related Production Order type: Process order order type '40' Production in charge quantities per order. Characteristics 2 Basic Functions of Process Orders Status management Production with production versions Scheduling Calculating capacity requirements Costing Batch number assignment Manufacture of co-products Availability checks Material quantity calculation Active ingredient management Batch determination Resource network Resource selection Generating control recipes for process control level Material staging with reservations Confirmation of quantities.
Process order management controls the whole process of the in-house production of products. Process order execution is integrated with the functions of capacity requirements planning. Material BOMs describe the structure of products that are produced in a company. In general. With regard to the production process. This quantity. The batches of one material are managed separately in stock. They are usually created and maintained from the master recipe integrated maintenance.
The master data of the master recipe describes the production of one or more materials in one production run without relating to a particular order. A production version determines which alternative BOM in combination with which master recipe is used for process order manufacturing. SAP defines a material as a substance or commodity that is bought or sold on a commercial basis.. The material is the central master record in logistics. It contains information that is used in the same manner over and over again.
The master data for resources describes the means of production in the production process. A batch is a uniquely identifiable partial quantity of a material. Material and Batch Batch Partial quantity of a material that is managed separately from other quantities of the same material in stock.
In contrast. A batch master record is usually created by the system in the background for certain business operations such as goods receipt. Users can also create batch master records directly in master data maintenance. Batches are created for a material. The characteristic batch specifications are assigned using characteristics from the classification system in the material master and are inherited by the corresponding batch master records.
A quantity of a material produced during a specific production run. Material Values: Vanilla ice cream Batch C1 Batch C2 7. If a material is to be produced and managed in batches. In production. A batch master record can be used to assign a batch to a material at different places along the supply chain.
A batch can be traced across the whole supply chain. If a batch is required in the supply chain with certain specifications. For example. Confirmations of material movements.. At the same time. The processing sequence of the phases is defined in relationships. In material quantity calculation. The material list is made up of components representing the materials entering and leaving the production process as well as temporarily existing materials and their planned quantities.
It also defines the assignment of these material components to phases of the order according to their appearance in the process. An operation is assigned exactly one resource. For a more detailed description of these steps. Status Material number Batch Prod.
Plant Doc. Order no. A number of settings must be made Customizing for each step to allow for successful order processing. The procedure involved in process order management can be divided into the following steps: If a process order is created without a planned order. When a planned order is converted. The BOM is not reread. A production version determines which alternative BOM in combination with which master recipe is used for production. Other functions scheduling or the availability check.
The process order data is created automatically this way. Inspection data is copied from the master recipe when an inspection lot is generated. Order creation with planned orders Planned order Material Material no. The goals and methods of resource scheduling for process orders are the same as those for work center scheduling for production orders. The material availability check for process orders is the same as the availability check for production orders.
You can classify material list components in classes of the class type Batch. Based on the selection criteria and a search strategy. This is how you define selection criteria for batch determination as characteristic values for material list components. The actual characteristics of a batch are also specified using characteristic values. Batches found in stock: Batch C1 Dextrose equiv. An availability check is performed at batch level. Selection criteria Dextrose equivalent: According to specific selection criteria.
Batch determination Search strategy Process order Material list. Potency of active ingredient: You can perform active ingredient management in a process order when using batch determination and material quantity calculation simultaneously. You can also define formulas for calculating phase quantities in material quantity calculation.
Various activities can be triggered automatically when an order is released: The process order must have status Released so that the business transactions for process order execution and process management can be executed.
You can release individual phases and operations. When an order is released. Process management includes the following functions: Receiving control recipes with process instructions from released process orders. Due to its flexible structure. Transferring control recipes to the corresponding process operators or process control systems Manual processing: The process instructions define in detail the process steps to be executed and the process data to be confirmed using process messages.
The staging of these parts for the process order can be done at a physical storage location or a dynamic one process order. For this type of staging. Pick parts are staged for the process order directly in the amount of the requirements quantity.
The stock situation in production and replenishment are taken into account. Crate parts are manually ordered when a crate is almost empty. They are explained in the unit Order-Controlled Production with Production Orders goods issue posting.
The simplest confirmation procedure is the confirmation for the process order. For phases and sec. The functions and procedures for manual entry for process orders are the same as those for production orders. The process instructions of the order define which process messages are requested by a PI sheet or a process control system. Confirmations are entered for phases and secondary resources and not for operations. You can define process messages in Customizing according to your own specific requirements.
Record material quantity. Display of information on process control instruction. It gives you the advantage of a flexible.
Stop heating and slow down agitator. Add material ABC. In connection with the process instructions contained in a control recipe. Record insp. XYZ test material Comments Operating group: W01 Control information Additional information Due to an error. Record time and temperature every hour. Input values Time The order data is therefore locked and cannot be changed. You can specify that a process order can only be created if an approved recipe exists.
You use the material identification function to check whether the material that was picked for the process order is completely available at the production line and will be used in the correct sequence. You use the material reconciliation function to analyze and verify the ingredients and yield at the end of the production process.
For batch specification. Approved recipe? With regard to product liability. You can exchange information about the product quality and analysis values between the production plant and the laboratory or the quality assurance system.
Food and Drug Administration FDA and other international institutions have become an international standard in many areas of process industries. You can perform a completeness check or sequence check at the start of: Picking complete?
PI sheet for production? Material identification Materials complete? Completeness check Materials in correct sequence? Completeness check Sequence check Automatic goods issue posting GI-posting after successful completeness or sequence check Automatic transfer of data from material identification to the batch record Check that picking is complete You use the completeness check to ensure that the materials that were picked for the process order are staged at the production line.
You use the sequence check to ensure that the sequence of the components to be used is correct. Results recording QM 4 Insp. There are several ways to record inspection results: You can use process messages to record inspection results.
In-Process Checks: Scenarios PI Insp. All versions are managed with their status in the header record of the batch record. A version of a batch record contains at most the following parts: A batch record consists of a current. Process Orders: Summary The use of process orders is an order-oriented production control option.
Process orders have specific characteristics. An additional essential characteristic is the use of functions for GMP-compliant production. An important characteristic is the option to process orders using process management. You will first get a general overview of the basic master data. Which menu path takes you to these transactions? Next you will display the master data production version.
You are a member of the SAP project team and responsible for implementing the functions of order-controlled production with process orders. Which task list and which BOM are assigned to each other via the production version? Finally you will display the newly created process order and become familiar with the structure. The planning run creates planned orders with regard to the planned independent requirements. Describe the current situation: Describe the new situation after the planning run: Creation of first planned order: Enter the following conditions for planned order selection: Planning plant: MRP controller: Time period of current week Choose process order type PI01 for conversion.
Write down the order number: Header Master Data Write down the production version: Describe the new situation after the planned order conversion: Compare the entries with the corresponding data in the master recipe. Get an overview of the detail data of a material component. Get an overview of the detail views of a phase. Notice that the Batch field is ready for input for components that are subject to batch management requirement. You will select and send the process messages created while you were processing the PI sheet in the message monitor.
After sending the messages. Process Order Release. You will maintain the PI sheet. At the same time generate the control recipe for the order. You will select your control recipe in the control recipe monitor.
Find out which activities were performed when the order was released. Enter the following criteria for order selection: Order type: Production sched. Processing an Order with a PI sheet At the conclusion of these exercises. Especially pay attention to REL.
In the production plant. Select and edit the PI sheet created when the control recipe was sent. Send the process messages. Maintain the PI sheet as specified in the solutions for this exercise. Send the control recipe and update the list display. Describe the new situation: MRP process order. Material and batch. Product cost planning For more information.
The basic master data is: Master data maintenance. T-FI1 Double-click the line for production version Lot size from to kg Task list Task list type: Group counter: T-FI1 Choose Enter. There are 3 future planned independent requirements which are not yet covered by material requirements planning. The system displays a warning and prompts you to check the input parameters. To start the MRP run. Multi-Level Material: Production version: I To display the components: Planned creation date The creation date is used as selection criteria for the collective conversion of planned orders into process orders.
The Collective Conversion of Planned Orders: List screen appears. Choose Back F3 to exit collective conversion. Select the corresponding line in the list and choose Convert. After the conversion. Time period of current week Process order type: PI01 Choose the Execute selections F8 icon. According to the selection criteria. Goods Receipt The Batch field is ready for input. Double-click the item number to display the detail data of a material component. The Batch field is ready for input for components subject to batch management requirement.
Double-click the phase number to display the detail view of a phase. Master Data Production Version: I Header. Choose the Execute selections F8 icon. PI01 T Delete the entries in the fields for date selection.
Order number Choose Enter. Choose Control recipe release with control recipe generation. The Release Process Order: After you have released the order and created the control recipe.
Order release: See status BASC "Batch assignment complete" See the automatically created batch number in the header data screen Goods receipt Material availability check: ICE Choose Enter. The control recipe has status Created.
Process order: Destination address: Select your control recipe and choose Send. After sending. The Control Recipe Monitor: Overview screen appears. The control recipe must now have status Sent. The quantities and batch numbers from the process order are set as the default values.
Operating group: The Process Message Monitor: Messages screen appears. The messages must now all have status Sent. The material component to be entered for the first phase can be found in the list of ingredients. Select all process messages and choose Send to send them. Process the other phases of the PI sheet in the same manner. Enter your signature to report the end of PI sheet. Enter your signature to report the end of phase Maintain Choose appropriate selection criteria.
The line operator can change these values. In the last phase at the end of the PI sheet. The General Data screen contains the component quantities withdrawn. Select one or more phases and double-click a phase number.
You can use the Previous operation and Next operation buttons to go to the dates of the individual phases. After the PI sheet has been completely processed. To display the activities calculated from the dates. Select one or more material components and the individual batch records for the materials to be handled in batches and double-click an item number. The produced quantity and confirmed order dates are displayed here in the General data.
The order header appears. To display the confirmed dates. Since a corresponding setting has been made. The plant stock was raised by the delivered quantity. Production Orders: Main Business Scenario Your company produces order-related products of some kind. You want to include functions for these important steps in order-related production: To implement production orders. You belong to the team that is implementing production orders in Production Planning and Scheduling.
Order-Controlled Production: 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 ERP Release You make all necessary settings in Customizing.
Order Category. Orders are one type of business transactions. 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. The course SCM covers a selection of the most important functions in detail. Characteristics 3 Extended Functions of the Production Order Production based on production version for example.
Scrap planning. Production order management controls the whole process of in-house production of products and is integrated in the functions of capacity requirements planning. Production order management uses the following system elements: Furthermore there are links or interfaces to quality management as well as external systems.
Application-Wide Processes Plnd ind. A special selection procedure chooses the valid routing. The routings are normal routings. Work centers are assigned in the routing of the operations. A special selection procedure chooses the valid BOM.
The most important data in the training system are: Material numbers R-F1 Pump make-to-order and make-to-stock prod.
R-B1 Casing make-to-stock prod. The production is organized based on the workshop principle. Components for final assembly that are not produced at the assembly production lines are transferred via the pull list from material stock. The final and pre-assembly as well as assembly production take place in the warehouse and partially as make-to-order production.
In plant pumps and their assemblies casing. R-B2 Stock make-to-stock prod. R-B3 Shaft make-to-order and make-to-stock prod. During confirmation of the assembly.. The individual parts for assembly production are transferred via picking or the pull list from material stock to production. 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.
Suboperations are permitted within an operation. At least one operation is required. Costs are determined at operation level. If necessary. You can make a selection from several alternative sequences.
You can create several parallel operation sequences. You have the choice of whether to assign material components.
If not otherwise specified in the routing. You can enter data manually. Such functions include costing. Inspection data is copied from the routing when an inspection lot is generated. The production order data is created automatically this way. A function is also available for the mass release of operations or orders see the section "Mass Processing".
Production orders are managed via status. An availability check can be executed automatically. You can release an individual operation. You can only do so if you create a special profile in Customizing beforehand. 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. The course SCM deals with capacity requirements planning in detail.
Detailed Scheduling Work Center Scheduling Goals Creation of a feasible work center schedule for executing operations of production orders Ensuring the time-based availability of capacities Optimum work center scheduling High capacity load utilization with shortest possible op.
Final assembly I labor cap. Paint shop labor cap. Final assembly I machine cap. Description Scheduling or rescheduling of operations: Planning Version Optimize.. Product chart Product Prod. Paint shop machine cap. Check instructions control the availability check. FFHM missing part. Availability Checks Material. Inspection results Assignment of confirmed quantity Partial quantities can be confirmed Material shortage status Missing part record Depending on the control.
For each order. It is possible to plot originals of documents using document distribution. Shop Floor Papers Standard. This is typical for small parts in containers. Here the required quantity is calculated from the target quantity of the components of the selected order that has been released.
Pick parts are staged for the production order directly in the amount of the requirements quantity. The staging of these parts for the production order can be done at a physical storage location or a dynamic one production order. This is typical for high value parts. Release order parts are manually ordered. This is typical for paint. This can take place manually or automatically.
The following functions are executed when a goods issue is posted. The GI posting is controlled via a movement type Point of consumption: Stock account Consumption acc. Generation of material documents.
A goods issue document can be printed. When you display the material document. The accounting document describes the goods movement from the financial accounting point of view. Determination of actual costs evaluation and update of order. The cost accounting documents serve various cost analysis purposes. Production Order: Storage location-related update of stock and consumption fields. Reduction of reservations for planned withdrawal.
The material document describes the goods movement from the materials management stock point of view.. Order confirmation is used for entering activities carried out within your company for an order.
Order Confirmation: For the most part. Each procedure realizes different requirements that a company may have. For further information on this interface. Update of plant activity The GR posting is controlled via a movement type A goods receipt document can be printed.
Credit to order.
Evaluation of the receipt. The following functions are executed when a goods receipt is posted. Update of the delivered quantity in an order. The material document describes the goods movement from the materials management stock point of view.
Order settlement credits the order. Settlement is usually periodic. It is controlled via a settlement profile. For more information about cost object controlling. It makes sense to use order-related COC for the following: 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.
Both order-related and product-related execution is possible. It makes sense to use product-related COC for the following: Make-to-stock production Repetitive production.
The production order also does not have any costs or any settlement rule. Selection at operation level to Work center to Plant Selection profile System status excl.
A log book is kept for background processing application log You can start mass processing with the options execute immediately. If orders are only marked.
Mass processing f. You can choose to have automatic stock postings in the intermediate steps. Individual orders can be added or deleted. The leading order can be created with an internal or external number. All orders have the same order type. Information Systems for Order Management Info. From the systems mentioned above. If the systems are used for list creation in individual production orders. Summary The use of production orders is an order-oriented production control option. An important characteristic of production orders is that they are used in discrete industries.
Production orders have specific characteristics based on how they are used in different industries and branches. The numerous special functions allow for a wide range of applications. As the production manager. In this exercise.
MRP controller or production scheduler. A Settings for User dialog box appears with several tabs. You are already on the General settings tab. Enter the following values: Checking rule for ATP display: PP Navigation profile: Berlin Becker Company.
Order number: Save the order and write down the order number and item. Use the following data: If the system suggests a different delivery date. Write down the number of the production order created. Double-click the order number. Number of the planned order: Production scheduler: Number of the production order: Order start date: Here the planned order number is still visible. Write down the numbers of the planned orders you converted: Planned order no.
Choose Production Order. Use collective conversion to do this. Write down any questions you may have about the meaning of the data fields and ask the trainer.
Choose the pushbutton PRT production resources and tools in the lower toolbar. Go to the operation overview and choose operation Item General data. Overview Choose: Notice the default release period. As the production manager or production scheduler. You will use the order information system to control this whole process. It starts with the release of production orders and ends with the goods receipt of the material produced. In this exercise you will perform the whole management process for a production order.
Function Release Execute function immediately Function parameters: Start the selection. What is the new status? Print all the shop floor papers for all the released orders of your production scheduler number.
Use mass processing to print the production orders. On the Mass processing — Printing of shop floor papers tab, make the following settings: Function Printing of shop floor papers Execute function immediately Function parameters: Original print The print mode original print prints all of the operations of the order that are not printed and are released. Check the print log for any errors. Use transaction SP01 to display and check the printing results.
Check the status changes in one of the production orders. 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.
Select all of the components in the list and choose Pick. If there is not enough stock to perform a material withdrawal, use transaction MB1C, movement type , to perform an other goods receipt for the material. Post a sufficient quantity. Look at the update in an order documented goods movements, withdrawal quantities, actual costs. Choose one of the orders processed so far for material R-F1 to perform confirmations. Perform a final confirmation quantity and time for operation Use the operation-related confirmation for the progress confirmation.
This type of operation-related confirmation confirms all operations automatically and by quantity. Display the confirmations performed for the order.
Look at the update actual quantities, status, costs in the order order header, operations. Check the material stock for material R-F1. Material stock: Check the status change in the production order. Post a goods receipt for the whole order quantity of a different production order for material R-F1.
Copy and Detail. Use the order information system to check the order progress for all production orders of your production scheduler number. Call up the order information system again with the following lists in the selection screen all other data remains the same List Documented Goods Movements List Operations List Object Overview.
For technical reasons, the system hides the layout and displays profile In the list generated, you can expand individual objects operations, components of an order. Production Types 1 Make-to-order prod. Production Types 2 Repetitive manufacturing Production line Kanban f l ful u ll full Period and quantity-oriented production Not order-related Unit 6 Replenishment-controlled using stock transfer.
Course Overview Contents: