make-to-stock - sap ui · make-to-stock july 28, 2012 2 ... chosen business processes in a...

Make-to-Stock

SAP Business ByDesign

Make-to-Stock

July 28, 2012 2

Table of Content

1 About this Document ....................................................................................................................... 3

1.1 Purpose .................................................................................................................................... 3

1.2 Reference System and Model Company .................................................................................... 3

2 Master and Organizational Data ...................................................................................................... 4

3 Business Process Tasks ................................................................................................................. 5

3.1 Make-to-Stock ........................................................................................................................... 5

3.1.1 Review Multi-Level BoM for Product P100401 ............................................................... 5

3.1.2 Create Forecast for Product P100401............................................................................ 6

3.1.3 Run MRP ...................................................................................................................... 6

3.1.4 Carry Out Load Leveling ................................................................................................ 8

3.1.5 Manual Capacity Adaptation ........................................................................................ 10

3.1.6 Release Production Proposal for Product P100109...................................................... 12

3.1.7 Review and Release Production Order for Product P100109 ....................................... 14

3.1.8 Confirm Production Tasks for Product P100109........................................................... 15

3.1.9 Review Production Order............................................................................................. 17

3.1.10 Check Journal Entry .................................................................................................... 17

3.1.11 Release Production Proposal for Product P100401...................................................... 18

3.1.12 Review and Release Production Order for Product P100401 ....................................... 19

3.1.13 Create Label ............................................................................................................... 21

3.1.14 Confirm Production Tasks for Product P100401........................................................... 22

3.1.15 Check Journal Entry .................................................................................................... 23

3.1.16 Overview of Product Planning Details .......................................................................... 24

3.2 Increase Inventory ................................................................................................................... 25

3.2.1 Check Available Stock ................................................................................................. 25

3.2.2 Create Purchase Order ............................................................................................... 26

3.2.3 Goods Receipt ............................................................................................................ 27

3.3 Connected Scenarios .............................................................................................................. 28

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1 About this Document

1.1 Purpose

The objective of this business scenario document is to give you hands-on experience of running the chosen business processes in a realistic business environment using the SAP Business ByDesign system. It allows you to quickly become familiar with this business scenario by guiding you through the steps that you need to carry out in the reference system.

To obtain a better understanding of the business processes that make up this scenario, also refer to the Scenario Outline for this scenario.

1.2 Reference System and Model Company

A reference system is a system that is preconfigured and loaded with fictitious users and sample data. The users and sample data are based on the model company Almika Inc.. By following the step-by-step instructions in this document, you can assume the identity of the Almika users and use the built-in sample

data to carry out each of the business process tasks. This hands-on experience will help you to understand the relevance and benefits of this business scenario.

To learn more about the model company that uses the business processes described in this document, read the Company Fact Sheet, which contains an overview of the reference

company, its organizational set up, employees and their different roles and work centers, as well as a comprehensive list of the master data used in your system.

You can find the Company Fact Sheet in the Help Center of your reference system. To access

this document, choose Help Help Center and open the link under the heading Company-Specific Help.

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2 Master and Organizational Data

Each SAP Business ByDesign Reference System contains essential master and organizational data, which

reflect the typical organizational structure of a mid-size company of a specific industry

allow you to run the industry specific processes using the appropriate master data, for example, materials, vendors or customers.

For this scenario, use the master data as described below.

If you want to run the scenario with customer and project-specific values, you can copy master data with certain characteristics from the sample entries in the table and adapt this data.

For an illustration of the organizational data as well as additional information (bill of material, logistics layout) about the reference company, refer to the Company Fact Sheet.

Master / Org. Data Type Name and Value Usage

Product P100401 Finished goods

P100109 1st level semi-finished goods

P100110 1st level semi-finished goods

P100515 Component

P100101 Component

Resource 100003 Resource used by producing product P100401

100001 Resource used by producing product P100109

Planning Area P1100

Logistics Area P1100 Logistic Area head internal warehouse

P1100-20 Logistic Area for warehouse in

internal warehouse

Supplier S100200

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3 Business Process Tasks

3.1 Make-to-Stock

3.1.1 Review Multi-Level BoM for Product P100401

What You Should Know

The Supply Planner gets an overview of the multi-level Bill of Material for product P100401.

Logon and Work Center Information

Logon ID (Role) SUPPLYPLANNER01P (Supply Planner / Richard Stone)

Work Center / View Planning and Production Master Data Production Bills of

Material

Procedure

Field Name Data to Enter Activity / Button / Comment

Production Bills Of Material view

Select the line item 100002 which reflects the product ID P100401.

Click Multi-Level Structure.

Multi-Level BoM Structure: 100002/VAR1 screen

Levels 2 Press Enter.

Click the Arrow beside every

product ID to check the assigned products. Or click Expand Expand All to

review the whole structure.

Click Close.

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3.1.2 Create Forecast for Product P100401


The Supply Planner creates a forecast for product P100401. Using the forecast demand, you can plan the periodic demand.



Work Center / View Supply Planning Common Tasks: Maintain Demand Forecast

Procedure


Maintain Demand Forecast screen

Product ID P100401

Period Type Monthly

Planning Area ID P1100

Start Date < current date > Click Go.

< Enter 200 each month for the next six months including

the current month >

In the Forecast Planning Table.

Click Save and Close.

3.1.3 Run MRP


The Supply Planner executes an MRP run for product P100401 to cover the demand forecast and to create dependant demand for the components and raw materials. The demands are passed through to all BoM levels. Multi-level supply planning ensures that the goods receipts for all required products are planned on time. The result of the planning run is displayed and the production proposals for the product are created.



Work Center / View Supply Planning Products

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Procedure


Products view

Show list Choose All Products by Selection.

Click Advanced.

Product ID P100401

Planning Area ID P1100 Click Go.

Select the line item reflecting product P100401 and click Open.

Review the product planning details for the product. The category Forecast allows you to

review the newly created demand forecasts.

Product Planning Details: P100401 / P1100 screen

Choose Run Planning Multi BoM Level.

Run Planning: Multi BoM Level screen

Click OK.

For every product of the Multi-Level BoM you receive the following information message:

Product P100xxx in planning area P1100 planned (with warnings).

Product Planning Details: P100401 / P1100 screen

Check the Supply and Demand List. Production proposals are generated to

cover the new demands.

Production proposals are generated to cover the new demands.

Click Add Product.

Add Product screen

Product ID P100109

Planning Area ID P1100 Click OK.

Repeat this step for the product IDs P100110, P100515, and P100101.

Product Planning Details: P100101/P1100 screen

Choose the Selected

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Products tab.

Selected Products tab

Select the line item reflecting product P100110.

Click Show Product Planning Details.

Product Planning Details: P100110/P1100 screen

Choose the Supply and Demand tab.

Supply and Demand tab

Check if the forecasted demand is passed to all levels

of the Multi-Level BoM.


Since you have run the MRP on a Multi-Level BoM level, production proposals are generated for product P100109 and – if necessary – purchase proposals are generated for product

P100110.

3.1.4 Carry Out Load Leveling


To resolve overload issue, capacity load leveling is carried out to balance the capacity load and the capacity of a resource has been increased.



Work Center / View Supply Planning Resource Load

Procedure


Resource Load view

Show list Choose All Resource Loads By Selection.

Click Advanced.

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Resource ID 100003 Click Go.

Select the line item reflecting resource 100003.

Check the actual load situation under Details: Resource-

100003 / P1100 Load Graph.

Click Open.

Resource Planning Details: 100003 / P1100 screen

Planning buckets with an overload are indicated with a red light in the Exception column. You

can click the Open Exception List to get more details.

Click Run Load Leveling.

Input Parameters for Run Load Leveling screen

Start Date As proposed

End Date Start Date + 1 month Exception should fall in this period. If not, please adjust the Start Date and End Date.

Resource Utilization % 100 Click OK.


Check the Exception column.

The overload situations should be resolved. You can click Load Graph to get a graphical

overview of the changed capacity and load situation.


If the overload situation is not resolved, please follow next steps and run load leveling again.

Resource Load view

Click the link to the Resource 100003.

Equipment Resource Overview: 100003 screen

Click View All.

Operating Times tab Standard Operating Times tab Operating Hours tab

Click Add Row under Operating Hours.

Start Time 17:00

End Time 18:00

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Operating Times tab Downtime and Additional Time tab

Click Add Row under Additional Times.

Reason Code Peak Time

Start Date < Saturday following the chosen planning bucket date >

09:00

End Date < Sunday following the chosen

planning bucket date >

9:00

Time Type Resource Specific Overtime


The daily capacity has been increased due to the additional shift. The capacity on one

weekend has been increased due to the Peak Time.

3.1.5 Manual Capacity Adaptation


The Supply Planner monitors an overload exception on a resource and reschedules the production proposals to an alternative source of supply.



Work Center / View Supply Planning Resource Load

Procedure


Resource Load view

Show list Choose All Resource Loads

By Selection.

Click Advanced.

Resource ID 100001 Click Go.

Select the line item reflecting

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resource 100001.

Check the actual load situation under Details: Resource-

100001 / P1100 Load Graph.

Make a note of the first day with a capacity demand.

Click Open.

If there is already a line item indicating an exception, you can select it, skip the next steps and continue with next Resource Planning Details: 100001 / P1100 view.


Click the link to the Resource 100001.

Equipment Resource Overview: 100001 screen

Click View All.

Operating Times tab Downtime and Additional Time tab

Click Add Row under Downtimes.

Reason Code Maintenance

Start Date < Start date = day you noted +

1 >

Skip weekend.

12:00

End Date < End date = day you noted +2 >

Skip weekend.

13:00

Time Type Resource Specific Downtime


Click Close.

Resource Load view

Click Refresh.

Select the resource ID 100001

and click Open.

Resource Planning Details: 100001 /P1100 screen

Planning buckets with an overload are indicated with a red light in the Exception column.

Select a line item that shows

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an overload exception and check the provided details on the Details: Operation List

tab page.

Select the first production proposal.

Choose Actions Change Source of Supply.

Change Source of Supply for Document XXX screen

Select the alternative source of supply (the one with NO green check mark of Current field).

Click Assign.


Click Save.

Click Close.

Resource Load view

Click Refresh.

Make sure that the overload exception disappears.

3.1.6 Release Production Proposal for Product P100109


The production of the cylinder P100109 is a prerequisite for the production of the gas boiler P100401. The Supply Planner releases the production proposals with the automatic creation of production requests and production orders. The production proposal is released and a production order is created.



Work Center / View Supply Control Process Production Proposals

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Procedure


Process Production Proposals view

Show list Choose All Proposals by Selection.

Click Advanced.

Product ID P100109


Select the line item which is

firmed.

Click Edit.

Production Proposals: XXX screen

Click Open Material Flow.

Material Flow for Reference Document: Production Proposal XXX screen

The Material Flow illustrates which production proposal of the Product ID P100401 is the

trigger for the actual production proposal of the product P100109.

Click Close.

Production Proposals: XXX screen

Click Release.

Monitor Production Requests view

Show list Choose All Requests By Selection.

and Find Enter the <production proposal ID> that you have

released before.

Click Go.

Select the line item reflecting the related production request ID.

Click View.

On the General tab page, you can see that the Status is now set to Production Order

Creation Started.

Document Flow tab

Check if a production order is created. Make a note of the

production order ID.

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Click Close.

The production proposal is converted to a production request.

3.1.7 Review and Release Production Order for Product P100109


The Production Planner releases production orders to the shop floor.


Logon ID (Role) PRODUCTIONPLANNER01P (Production Planner /

Samantha Wolfe)

Work Center / View Production Control Production Orders – By Order Header

Procedure


Production Orders view

Show list Choose All Production Orders.

and Find Enter the <production order ID> that you have noted

before.

Click Go.

Select the appropriate line

item.

Click Edit.

Production Order: XXX screen General tab

Review the related business objects such as the Production Request ID or the Released Execution Model.

Order Structure tab

Review the production order details.

Document Flow tab

Review the document flow of the production order.

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Click Stock and Demand Overview.

Stock and Demand Overview screen

Check if there is enough stock on hand for the components

P100110 and P100515.

Click OK to close the window.

Production Order: XXX screen

Click Release.

Click Close.

3.1.8 Confirm Production Tasks for Product P100109


After finishing the production, the Production Operator confirms the production tasks. All production tasks are executed and the product P100109 is produced.


Logon ID (Role) PRODUCTION02P (Production Operator / Michael Peacock)

Work Center / View Execution My Task Folders

Procedure


My Task Folders view

Select the line item reflecting 100005 - Production Tasks.

Click Open Task List.

Task Folder: 100005 Production Tasks screen

Select the line items reflecting your production order ID.

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There are two line items for your production order. The quantity of the tasks is determined by the production model through the task generation method, for example, ‘Operations including

Reporting Points‘, and the operations / activities.

For one task the Start Feasibility is green, for the other task the Start Feasibility is red. Select the line items reflecting your tasks and under Details, choose the Sequence tab. It

shows which of the two tasks is the Predecessor and which the Successor.

Select the line item where the Start Feasibility is green for

your production order ID.

Click Confirm.

Task Details: XXX Reporting Point screen

Click Confirm as Planned.

Make sure that the Confirmation Finished flag is set.

Review the Output Products, Input Products, and the

Activities.

Choose Change Status Finish.

Input Parameters for Finish screen

Click OK.

Task Details: XXX Reporting Point screen

Click Close.


Click Refresh.

Select the line item reflecting the successor task for your


Repeat the above-mentioned

confirmation steps.

The input products P100110, P100515 and the only output product P100109 are in the second task. The input product quantity corresponds to the confirmed quantity. The operation IDs are maintained in the production model. The confirmed durations of the operations correspond to

the confirmed quantity.

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3.1.9 Review Production Order


The Production Planner reviews the production order confirmations.


Logon ID (Role) PRODUCTIONPLANNER01P (Production Planner / Samantha Wolfe)

Work Center / View Production Control Production Orders

Procedure


Production Order view


Select the line item reflecting the production order ID you

noted down before.

Click Edit.

Production Order: XXX screen Execution Monitor tab

Review all confirmations executed for this production

order.

3.1.10 Check Journal Entry


Fully integrated and automated financial accounting is one of the key capabilities of the system. Provided that the financial master data has been correctly defined and the required fine tuning settings for account determination have been adjusted, journal entries will be posted automatically. Authorized users can check and monitor these postings any time, for example the completeness and details of the financial postings including the complete document flow.


Logon ID (Role) FINANCIAL02 (Accountant / Iris Green)

Work Center / View General Ledger Journal Entries Journal Entries

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Procedure


Journal Entries view

Show list Today’s Postings As an alternative, you can choose Last 3 Days’

Postings or All Postings.

Group By list Journal Entry Type Click Go.

Click Advanced to limit your search criteria to the

documents you want to check.

Related Source Document ID

Enter the previously created production order ID

Related Source Document Type

96 - Production Lot Click Go.

Click View to see the details of

the posting.

Select the Document Flow

tab to view the complete

document history.

Click Close.

3.1.11 Release Production Proposal for Product P100401


After the production of the cylinder P100109, the production of the gas boiler P100401 can start. The Supply Planner releases the production proposal with automatic creation of production requests, production orders, and production tasks.



Work Center / View Supply Control Process Production Proposals

Procedure


Process Production Proposals view

Show list Choose All Proposals by Selection.

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July 28, 2012 19


Click Advanced.

Product ID P100401


Select the line item reflecting the closest production proposal ID and make a note

of it.

Click Release.

Monitor Production Requests view

Show list Choose All Requests By Selection.

and Find Enter the <production proposal ID> that you have

released before.

Click Go.

Select the line item reflecting the related production request

ID.

Click View.

Document Flow tab

Check if a production order is created. Make a note of the


Click Close.

3.1.12 Review and Release Production Order for Product P100401


The Production Planner releases production orders to the shop floor.




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July 28, 2012 20

Procedure




And Find Enter the <production order ID> that you have noted

before.

Click Go.

Select the appropriate line item.

Click Edit.

Production Order: XXX screen General tab

Review the related business objects such as the Production Request ID or the

Released Execution Model.

Order Structure tab

Review the production order details.

Document Flow tab

Review the document flow of

the production order.

Click Stock and Demand Overview.

Stock and Demand Overview screen

Check if there is enough stock on hand for the components

P100101 and P100109.

Click OK to close the window.

Production Order: XXX screen

Click Release.

Click Close.

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3.1.13 Create Label


The Production Planner creates labels for the output product. On the serialized product labels where there is one label per product, it is possible to capture the serial number identification.




Procedure




and Find Enter the <production order ID> that you have noted

before.

Click Go.

Click New Labels.

New Labels screen

Label Type Select Serialized Product.

The Quantity on Label field is automatically set to 1ea. And the Number of Labels field is

calculated to 200 if the produced quantity is 200ea.

General tab

Comment on Label Released by Samantha Wolfe

Serial Number tab

Next Serial Number &+20100811_{001} Press Enter.

Click Create Serial Numbers.

Click Save. The system

generates the label IDs.

Make a note of the label IDs.

Click Close.

Common Tasks view

Click Labels.

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Labels screen

Show list Choose All Labels By Selection.

Product ID P100401

Created On < current date > Click Go.

Select the appropriate line item.

Click View.

Label Overview screen

Choose Preview

Check the Serial Number and

if the note is added.

Click Close.

Click Close.

3.1.14 Confirm Production Tasks for Product P100401


After finishing the production, the Production Operator confirms the production tasks. All production tasks are executed and the product P100401 is produced.


Logon ID (Role) PRODUCTION02P (Production Operator / Michael Peacock)

Work Center / View Execution My Task Folders

Procedure


My Task Folders view

Select the line item reflecting 100005 - Production Tasks.

Click Open Task List.


Select the line items reflecting

your production order ID.

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Click Confirm.

Task Details: XXX screen Assigned Labels tab

Select the Label ID you want

to assign. Use the Shift key to

select the first and last rows.

Click Assign and Add Quantity.

Choose Change Status Finish.

Input Parameters for Finish screen

Click OK.

Task Details: XXX screen

Click Close.


Click Refresh.

3.1.15 Check Journal Entry


Fully integrated and automated financial accounting is one of the key capabilities of the system. Provided that the financial master data has been correctly defined and the required fine tuning settings for account determination have been adjusted, journal entries will be posted automatically. Authorized users can check and monitor these postings any time, for example the completeness and details of the financial postings including the complete document flow.


Logon ID (Role) FINANCIAL02 (Accountant / Iris Green)

Work Center / View General Ledger Journal Entries Journal Entries

Procedure


Journal Entries view

Show list Today’s Postings As an alternative, you can choose Last 3 Days’

Postings or All Postings.

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Group By list Journal Entry Type Click Go.

Click Advanced to limit your search criteria to the

documents you want to check.

Related Source

Document ID Enter the previously created

<production order ID>

Related Source Document Type

96 - Production Lot Click Go.

Click View to see the details of

the posting.

Select the Document Flow tab to view the complete

document history.

Click Close.

3.1.16 Overview of Product Planning Details


The Supply Planner gets an overview of the product planning details after the production.



Work Center / View Supply Planning Products

Procedure


Products view

Show list Choose All Products by

Selection.

Click Advanced.

Product ID P100401


Select the line item reflecting product P100401 and click Open.

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July 28, 2012 25


Product Planning Details: P100401 / P1100 screen Supply and Demand tab

Ensure that the available stock has increased by 200 ea compared to the beginning of

the scenario.

Click Add Product.

Add Product screen

Product ID P100109

Planning Area ID P1100 Click OK.

Repeat this step for Product IDs P100110, P100515 and P100101.

Product Planning Details: P100401 / P1100 screen Selected Products tab

Select the line item reflecting product P100110.

Click Show Product Planning Details.

Supply and Demand tab

Check the available stock.


The available stock of the components P100110, P100515 and P100101 has decreased. The

available stock of P100109 has not changed.

3.2 Increase Inventory

3.2.1 Check Available Stock


The Warehouse Manager checks the available stock.


Logon ID (Role) WAREHOUSE01P (Warehouse Manager / Luther Loblanski)

Work Center / View Internal Logistics Common Tasks: Stock Overivew

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Procedure


Stock Overview screen


Under Stock Details, review the data provided in the On-Hand Stock field related to the products in different logistics areas. For example, as compared to the required stock in chapter

3.1.3.

Click Close.

3.2.2 Create Purchase Order


The Buyer creates purchase orders.


Logon ID (Role) PURCHASE02 (Buyer / Bill Warner)

Work Center / View Purchase Requests and Orders Common Tasks: New Purchase Order

Procedure


New Purchase Order screen

Product ID Requested product, for example, P100110

Ship-To/Service-Location P1100

Quantity Requested quantity

Click Assign Source of Supply.

Select a source of supply.

Click Assign.

If no source of supply could be determined, you must manually choose a Gross Price and a

Supplier ID, for example, S100200.

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July 28, 2012 27


If you want to purchase further products, repeat the above steps for the requested products.

Click Order.

Make a note of the purchase order.

3.2.3 Goods Receipt


The Supply Planner posts the goods receipt for a purchase order.



Work Center / View Inbound Logistics Purchase Orders

Procedure


Purchase Orders view

Show list Choose All Purchase Orders by Selection.

Click Go.

Click the Display Filter Row

icon.

Purchase Order ID Enter the previously created <purchase order ID>.

Press Enter.

Select the line item reflecting the appropriate purchase order.

Click Post Goods Receipt.

Create Inbound Delivery and Goods Receipt screen

Delivery Notification ID Enter the <delivery notification

ID> of the supplier, for example, 90816.

Make sure that the Target Logistics Area ID is P1100-20.

Click Propose Quantities.

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July 28, 2012 28



The complete process of creating a supplier invoice is covered in the business scenario document Procure-to-Pay (Stock). The process of paying a supplier invoice is covered in the business scenario document Cash and Liquidity Management – Processing Payable and Payment.

3.3 Connected Scenarios

For Increasing Inventory the subsequent step of creating a supplier invoice is documented in the business scenario document Procure-to-Pay (Stock). The subsequent step of paying a supplier invoice is documented in the business scenario document Cash and Liquidity Management (Processing Payables and Payments). Those steps are typically done for a batch of invoices and payments and not

for one specific payment or invoice.

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July 28, 2012 29

Icons

Caution

Example

Tip

Note

User ID and User Role

Work Center and Work Center View

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