make–to–stock production – process industry

SAP Best Practices Make-to-Stock Production – Process Industry (146): BPD

EHP4 for SAP ERP 6.0

June 2009

EnglishEnglish

Make-to-Stock Production – Process Industry (146)

SAP AGDietmar-Hopp-Allee 1669190 WalldorfGermany

Business Process Documentation

1.

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Contents

1 Purpose 5

2 Prerequisites 6

2.1 Master Data and Organizational Data 6

2.2 Business Conditions 7

2.3 Roles 8

2.3.1 Defining Queries for Personal Object Worklist (POWL) 8

2.4 Preliminary Steps 9

2.4.1 Creating User Settings for Requirement Planning 9

3 Process Overview Table 10

4 Process Steps 11

4.1 Anonymous Forecast and MRP 11

4.1.1 Creating Planned Independent Requirements 11

4.1.2 Material Requirements Planning at Plant Level 12

4.1.3 Evaluation of the Stock/Requirement List 14

4.2 Procurement to Stock 15

4.3 Capacity Planning 17

4.3.1 Capacity Evaluation 17

4.3.2 Changing Planned Order Schedule 18

4.4 Process Order Processing 19

4.4.1 Converting Planned Order to Process Order 20

4.4.2 Checking Material Availability – Missing Parts List 21

4.4.3 Material Staging for Production 22

4.4.4 Multilevel Order Report 23

4.4.5 Goods Issue of Batch-Managed Components 24

4.4.6 Posting Goods Receipt for Process Order 26

4.4.7 Confirmation of Production after Goods Receipt Posting 28

4.4.8 Goods Issue for Backflushed Components during Confirmation 29

5 Follow-up Processes 30

6 Appendix 30

6.1 Reversal of Process Steps 30

6.2 SAP ERP Reports 32



Make-to-Stock Production – Process Industry

2. PurposeThe scenario Make-to-Stock Production – Process Industry focuses on:

● Sales-order-independent production using MTS (Make-to-stock) production / process order processing.

● MRP planning with planned independent requirements gives planned orders for production as well as purchase requisitions for raw materials.

● Planned orders are converted into process orders.● Components are staged to the shop floor location.● Batch-management components are issued at production start immediately, semi-

finished and finished products produced, in conjunction with batch management.● Backflushing is used for the packaging material (without batch management) at finished

product confirmation.● Process order confirmation triggers order controlling and settlement.● Planned Independent Requirements Creation

The process can be started with two different starting points:

○ start with SOP (Sales Operation Planning) proceed scenario Quarterly Plan - Sales Quantity Forecast with CO-PA (179) or scenario Logistics Planning (144) and start Make to Stock – Process Industry with the second step Material Requirements Planning (MRP)

○ start with creating Independent Requirements manually proceed Make to Stock – Process Industry with the first step

Irrespective of the starting point you choose, the result is independent requirements for your BOM header material, which are then used as input for MRP planning.

● Material Requirements Planning (MRP)

The daily MRP run generates replenishment elements at each low-level code. The system automatically generates purchase requisitions for purchased parts within the 3-month opening period for the planned order. The system uses planned orders to implement receipt elements, which are also required.

In general, the system also creates planned orders for parts, which will be produced internally. When the planned opening date has been reached, these planned orders are converted to process orders by the production planner. As a result, the system reserves all of the required components.

Capacity requirements have been created for planned orders and process orders, allowing capacity evaluation for the required resources at each level. Order schedules may be changed in case of capacity overload, requiring MRP run again in order to reschedule dependent material requirements.

Some materials (for example, the Raw Material Batch 3 (R30)) are planned on a consumption basis. Since these materials do not have storage restrictions due to shelf-life-management, larger quantities of this material can be stored in the warehouse. Replenishment orders are triggered as soon as a specified reorder point is reached.

● Make-to-stock production for semifinished and finished products

The production planner converts the planned orders with selection of start date. It is assumed that material availability at the plant is assured due to prior MRP planning. The components are usually stored at the general warehouse location, and staged to the shop floor level as requested for daily production.

In order to ensure data consistency (batch-managed components such as ingredients are issued with the same batch number as physically used), goods issue with order reference is posted at



production start. Backflushing can be used for non-batch-managed components such as packaging materials.

While the semifinished material production still is running, it is already handed over to the next line as input material for the finished product. Therefore the goods receipt postings are done for partial quantities already, allowing their immediate consumption for the next production step and thereby also ensuring batch traceability.

Once the daily production run for the semifinished product is finished, the sum of the produced quantity (as well as the additional scrap quantity) is transferred into the final order confirmation. Generally, only the last operation phase is confirmed, thereby confirming prior operation phases via milestone confirmation. Only in case of exceptions such as unplanned scrap earlier operation phases may be confirmed step by step.

Final confirmation updates process order status automatically, then triggering production controlling. Variance analysis and order settlement may be performed distinctively for every finished order, or as part of period end closing, dependent on reporting requirements.

3. Prerequisites

1. Master Data and Organizational DataDefault Values

Essential master and organizational data was created in your ERP system in the implementation phase, such as the data that reflects the organizational structure of your company and master data that suits its operational focus, for example, master data for materials, vendors, and customers.

The business process is enabled with this organization-specific master data, examples are provided in the next section.

Operational Focus

SAP Best Practices delivers standard values for more than one operational focus area, such as Services, Trade or Manufacturing. This means that you may find more than one master data table below. Use the master data that matches the operational focus of your company (Service, Manufacturing or Trading).

Additional Default Values

You can test the scenario with other SAP Best Practices default values that have the same characteristics.

Check your SAP ECC system to find out which other material master data exists.

Using Your Own Master Data

You can also use customized values for any material or organizational data for which you have created master data. For more information on how to create master data, see the Master Data Procedures documentation.

Use the following master data in the process steps described in this document:

Manufacturing / Trading

Master data Value Comments

Material F29 MTS processing for process industry with batch



processing

S24 Semifinished Product PI, batch managed

R15 Packaging material, no batch, external procured

R09 Raw material, batch-managed, external procured



Master Recipe MR-50001 Master Recipe S24 - Ink (Process)

MR-50002 Master Recipe F29 - Bottled Ink (Batched-Process)

Plant 1000 Production plant

Storage Location 1020 Production storage location

1030 Shipping storage location

1050 Stores storage location

Bill of Material StructureThis overview shows the bill of material structure and the usage of each component.

Material LevelMaterial type

Unit Characteristic of material

F29 0 FERT BT MTS processing for process industry with batch processing

R15 1 RAW PC Packaging material, no batch, external procured

S24 1 SEMI CCM Semifinished Product PI, batch managed

R09 2 RAW KG Raw material, batch-managed, external procured

R19 2 RAW L Raw material, batch-managed, external procured

R30 2 RAW L Raw material, batch-managed, external procured

2. Business Conditions



The business process described in this Business Process Documentation is part of a bigger chain of integrated business processes or scenarios. As a consequence, you must have completed the following processes and fulfilled the following business conditions before you can start going through this scenario:

Business condition Scenario

You have completed the following steps described in the Business Process Documentation Prerequisite Process Steps (154):

● Roll MM Period to Current Period. Perform this activity if the MM period in the system is not set to the current period. Usually, this activity has to be done once a month.

● Product Costing: Costing Run

Prerequisite Process Steps (154)

To run through this scenario, the forecast for the finished product have do be planned.

To execute this activity, run the Business Process Documentation for Logistics Planning (144) scenario.

This scenario is optional – you can also start the scenario with creating the planned independent requirements in the first process step.

Logistics Planning (144)

3. Roles

UseThe following roles must have already been installed to test this scenario in the SAP NetWeaver Business Client (NWBC). The roles in this Business Process Documentation must be assigned to the user or users testing this scenario. You only need these roles if you are using the NWBC interface. You do not need these roles if you are using the standard SAP GUI. You do not need these roles if you are not using the NWBC interface, but the standard SAP GUI.

PrerequisitesThe business roles have been assigned to the user who is testing this scenario.

Business role Technical name Process step

Employee (Professional User)

SAP_NBPR_EMPLOYEE-S Assignment of this role is necessary for basic functionality.

Production Planner

SAP_NBPR_PRODPLANNER-S MD02, MD04, MD12, COR8, CO24, CM05; MD61

Shop Floor Specialist

SAP_NBPR_SHOPFLOOR-S MF60, COOISPI, COIK, COR6N

Warehouse Clerk SAP_NBPR_WAREHOUSECLERK-S MIGO



Production Supervisor

SAP_NBPR_PRODPLANNER-M CM05


SAP_NBPR_SHOPFLOOR-S COOISPI, Material Document List

1. Defining Queries for Personal Object Worklist (POWL) The following queries must be defined to test this scenario in the SAP NetWeaver Business Client (NWBC). You only need these queries if you are using the NWBC interface. You do not need these queries if you are using the standard SAP GUI.

The queries are necessary to access role specific worklists in the SAP NetWeaver Business Client (NWBC).

For more information on the creation of queries, see the section Creation of Queries in Personal Object Worklists (POWLs) in the Quick Guide to Implementing the SAP Best Practices Baseline Package (DE) document.

Business role

Application Object Type Variant Name

Variant Selections

Selection Criteria

Query Name


Capacity Overview

PRPL_CAPACITY_LOAD - - Plant: 1000

Work Center (Mixing) or

(Bottling) or

(Packing)

e.g. Capacity Overview

ResultYou can now process the scenario Make-to-Stock Production - Process Industry (146).

4. Preliminary Steps

1. Creating User Settings for Requirement Planning

UseIn this step, you set up user settings that are necessary for requirement planning.

Procedure1. Access the transaction choosing one of the following navigation options:

Option 1: SAP Graphical User Interface (SAP GUI)

SAP ECC menu Logistics Materials Management Inventory Management Environment Stock-Stock/Requirements List

Transaction code MD04



Option 2: SAP NetWeaver Business Client (SAP NWBC) via Business Role

Business role Production Planner

(SAP_NBPR_PRODPLANNER-S)

Business role menu Production Evaluations Reports Display Stock/Requirements Situation

2. On the Stock/Requirements List: Initial Screen, make the following entries:

Field name Description User action and values Comment

Material number Finished Product PI (F29)

Plant Plant 1 (1000)

3. Choose Enter and confirm the information message.4. Navigate to Environment Navigation Profile Assign (NWBC: More… Environment

Navigation Profile Assign).5. Select the General Settings tab page. 6. In the Navigation Profile field, choose the navigation profile SAPPPMRP00 MRP

Controller.7. Choose Save and confirm the information message.8. Go back to the menu.

ResultYou have created the user settings necessary for the requirements planning.

4. Process Overview Table

Process step External process reference

Business condition

Business role

Transaction code

Expected results

Logistics Planning (Optional)

Logistics Planning (144)

See logistics planning scenario




Create Planned Independent Requirements

Production Planner

MD61 Independent requirements for finished product is created

Material Requirements Planning at Plant Level

Production Planner

MD02 Independent requirements for finished product were planned

Evaluation of the Stock/Requirement List

Production Planner

MD04 Stock/requirements situation for the



planned materials is analyzed

Procurement of Stock

Procurement of Stock Material (130)

See scenario Procurement of stock



Sufficient stock for all raw or semi-finished products in this scenario is available

Capacity Evaluation


CM05 Capacity checked and rescheduled if necessary

Change Planned Order Schedule

Production Planner

MD12 The planned order is firmed

Convert Planned Order to Process Order

Production Planner

COR8 The system generated process order(s)

Check material availability – missing parts list

Production Planner

CO24 Material availability is checked for all relevant process orders

Material Staging for Production


MF60 All materials, needed for the process order were moved from various storage locations to the production storage location

Multilevel Order Report


COOISPI Worklist for process orders, components and operations

Pick Components (picking list)


COIK The goods movements have been posted

Goods issue manually (instead of picking list)


MIGO The goods movements have been posted



Post Goods Receipt for Process Order

Warehouse Clerk

MIGO The goods receipt for the process order is posted

Confirmation of Production after Goods Receipt Posting


COR6N Final confirmation of the last operation has been carried out

Goods Issue for backflushed components during confirmation


COR6N Backflushed components are issued with the confirmation posting automatically

Period End Closing (only once a month)

Period end closing “general” Plant (181)

See period end closing scenario




5. Process Steps

1. Anonymous Forecast and MRP

1. Creating Planned Independent Requirements

UsePlanned independent requirements are used to perform demand management functions. A planned independent requirement contains one planned quantity and one date, or a number of planned independent requirements schedule lines, that is, one planned quantity split over time according to dates.

Use this step if you have not run the scenario Logistics Planning (144) first.

Instead of creating single requirement, sometimes a requirements plan which includes one or more planned independent requirements can be maintained for mass processing. In this case, the requirements are grouped and maintained under a requirement plan number.



SAP ECC menu Logistics Production Production Planning Demand Management Planned Independent Requirements Create







Business role menu Production Production Planning Demand Management Create Planned Indep. Requirements

2. On the Create Planned Independent Requirement: Initial Screen, make the following entries:


Planned Independent Requirements for

Material Finished Product PI (F29) You have to select the radio button.


Selection parameters

Version 00

Planning horizon

FromChange system default if necessary.

To

Planning period

Week W

3. Confirm your entries with Enter.4. On the Plnd ind. reqmts Create: Planning Table screen, enter the quantity of the

independent requirements for a particular point in time or over a specific period of time for the material. (For example, set planned quantity 10.000 for each time interval).

5. Confirm with Enter.6. Save your data and choose Back to return to the menu.

2. Material Requirements Planning at Plant Level

Use



The aim of material requirements planning is to tailor available capacities and receipts on time to suit requirements quantities. You can use MRP or consumption-based planning for this purpose. Single-item multi-level requirement planning is carried out for plant 1000.

PrerequisitesThe finished product for PI (F29) is planned at plant level. There is now a requirement for the material Finished Product PI (F29) in plant 1000.



SAP ECC menu Logistics Production MRP Planning Single-Item, Multi-Level





Business role menu Production MRP Planning MRP - Single-Item, Multi-Level

2. On the Single-Item, Multi-Level screen, make the following entries:


Material Finished Product PI (F29)


Scope of planning

Product group

MRP control parameters

Processing key NETCH

Create purchase req. 1 (Purchase requisitions)

Delivery schedules 3 (Schedule lines)

Create MRP list 1 (MRP list)

Planning mode 3 (Delete and recreate



planning data)

Scheduling 2 (Lead time scheduling and capacity planning)

Process control parameters

Also plan unchanged components

(remove indicator)

Display results before they are saved

(remove indicator)

Display material list (remove indicator)

Simulation mode (remove indicator)

3. Confirm your entries with Enter.4. Confirm the information message Please check input parameters.5. Go back twice to return to the menu.

3. Evaluation of the Stock/Requirement List

UseAfter the requirements planning has been carried out you want to display the stock/requirements situation for the material Finished Product PI (F29) in the stock/requirements list.

PrerequisitesThe requirements planning has been carried out.



SAP ECC menu Logistics Production MRP Evaluation Stock/Requirements List



Business role Production Planner (SAP_NBPR_PRODPLANNER-S)

Business role menu Production Evaluation Reports Display Stock/Requirements Situation

2. On the Stock/Requirements List: Initial Screen make the following entries:




Material Finished Product PI (F29)


3. Confirm your entries with Enter.4. From the menu, choose Environment Total reqmts display. Using SAP NWBC choose

More… Environment Total reqmts display. Here you can see all the planned independent requirements for the material and the corresponding allocation status at a glance. All sales orders are listed, regardless whether or not they have been allocated.

5. Choose Back to return to the Stock/Requirements List: Initial Screen.6. Display the Stock/Requirements List as of <o’clock> Hrs screen again for the following

materials:


Material Semi finished Product PI (S24)



Material Packaging Material (R15)



Material Raw Material Batch 1 (R09)










7. Choose Back twice to return to the SAP Easy Access screen.

ResultThe BOM explosion during the MRP run has generated dependent requirements for the demand-driven planned components. Dependent requirements for the consumption-based components are generated by production orders (planned orders and process orders) at the time of reservation. Therefore MRP run also generated dependent requirements for the components. If inventory does not cover the requirements, planned orders are created for in-house-produced materials and purchase requisitions for externally procured materials.

For R30, no requirements are created since this material is set as bulk material.

2. Procurement to StockIn the real business case, the raw materials are usually purchased from external vendors, which can be covered by the standard purchasing processing.

You have the option either to post initial stock directly to the storage location or reference to the sub process Procurement w/o QM (130).

First check in previous step (MD04), whether purchase requisition is generated for the material. If not, then there is sufficient stock available.

Procurement w/o QM (130)

UseIn this scenario, we have several materials (raw or semi finished) to be procured.

ProcedureTo execute this activity process the following steps using the master data from this document (see also table below):

Steps to process from scenario Procurement to Stock - 130

Display List of Purchase Requisitions to be assigned

Evaluation of the Stock/Requirement List

Convert Assigned Requisitions to Purchase Orders

Approval of Purchase Order

Print Purchase Order



Receive Goods from Vendor to the Purchase Order

Master Data

Field name User action and values Comment

Material R15 Raw Material, Packaging material, no batch

Material R09 Raw material, batch managed (FIFO-Strategy)



Vendor 300001

Purchasing org. 1000

Purchasing group 100, 101, 102, 770 840 9424

Material R15 – Purchasing group: 100



Material R30 – Purchasing group: 770 840 9424

ResultMaterials are available in stock.

Optional: Initial Stock Posting1. Access the transaction choosing one of the following navigation options:


SAP ECC role menu Logistics Materials Management Inventory Management Goods Movement Goods Receipt Other

Transaction code MB1C


Business role Warehouse Clerk



(SAP_NBPR_WAREHOUSECLERK-S)

Business role menu Warehouse Management Consumption and Transfers Other Goods Receipt

2. On the Enter Other Goods Receipts: Initial Screen, enter the following data:


Movement Type 561

Plant 1000

Storage Location 1050

Document date <previous month>

Posting date <previous month>

3. Choose Enter.4. On the Enter Other Goods Receipts: New Items screen, enter the following data

according to the table below:

To enter more than nine items, choose Create to open a blank page.

Material Quantity

<Material number> <Required quantity>

5. Choose Enter.6. Choose Save.

ResultInitial stock for the material is posted. Make a note of the material document number

_______________________.

3. Capacity Planning

1. Capacity Evaluation

UseIn this activity, the capacities are checked for overload on bottleneck resources. The selection of capacity requirements for leveling is based on the Change Time Period parameters on the selection screen. The default is four weeks out.

During MRP, planned orders are created and scheduled in order to meet the material requirements. MRP run does not check capacity loads. If a resource is used for the production of more than one material (or if individual requirements are created for the same material at the same day) capacity overload may occur. Alternatively, it may be required to optimize capacity utilization via reduction of idle times through sequential scheduling planned orders (optimization



of capacity utilization and rescheduling via “drag & drop” using the graphical planning table is not part of this building block).

After running this activity, check the capacity leveling.

Option A: If the capacity leveling is OK, go to step 4.4.1 (convert planned order to process order)

Option B: If the capacity level is not OK, go to step 4.3.2 (change planned order schedule)



SAP ECC menu Logistics Production - Process Process Planning Evaluation Resource View Overload

Transaction code CM05

2. On the Capacity Planning: Selection screen, make the following entries:


Work center Resource 1 (Mixing) or

Resource 2 (Bottling) or

Resource 3 (Packing)

Optional


3. Choose Settings General and change the time period to day 4. Choose Settings Evaluations Standard Overview. Maintain 10% as minimum load.5. Choose Standard overview.

Capacity requirements are displayed, in comparison with available capacity and capacity load.

6. Choose Back twice to return to the SAP Easy Access screen or proceed with the next chapter.


Business role Production Supervisor

(SAP_NBPR_PRODPLANNER-M)

Business role menu Production Evaluation Capacity Overview

1. Select the active query Capacity Overview (Query name as defined in chapter 2.3.1)2. Mark the work center line to enable the capacity utilization section.3. To review the Capacity Requirements per Work Center and period, select a cell in the

Capacity utilization section.4. Close the window to return to the SAP NWBC screen.



ResultYou have checked the capacity requirements.

2. Changing Planned Order Schedule

UseYou can change the order schedule to avoid capacity overloads at bottleneck resources or to sequence orders for resource utilization optimization.

ProcedureFrom within capacity overload check, you can progress with

1. Select the line detail and choose Cap. details/period.2. To change a planned order or process order, select the requirements line and choose

Order header. Select Planned order.3. You can now change the scheduling dates by changing the order finish date (as default,

planned orders are scheduled backwards), then select Schedule planned order.4. Save the order and refresh the capacity load overview.

Alternatively, you can change the planned orders directly:

1. Access the transaction choosing one of the following navigation options:


SAP ECC menu Logistics Production - Process Production Planning MRP Planned Order Change


2. On the Change Planned Order: Initial Screen, make the following entries:


Planned order number <Order number>

3. Change the scheduling dates by changing the order finish date (as default, planned orders are scheduled backwards).

4. Select Schedule planned order.5. Save the order.




Business role menu Production MRP Planned Order

1. On the All Planned Orders screen, select <your Planned Order> and choose Change Planned Order.

2. Change the scheduling dates by changing the order finish date (as default, planned orders are scheduled backwards).

3. Choose Schedule planned order.4. Save the order.



ResultCapacity requirements are rescheduled and the planned order is firmed, so that another MRP run do not change order scheduling.

4. Process Order Processing

In this scenario, the production process has to be executed at first for the semi finished material (S24) and afterwards for the finished product (F29).

1. Converting Planned Order to Process Order

UseIn this activity, you create process orders. Order release is executed automatically, so that production may start immediately.



SAP ECC menu Logistics Production Process MRP Planned Order Convert to Proc. Ord. Collective Conversion

Transaction code COR8




Business role menu Production MRP Planned Order Collective Conversion of Planned Orders

2. On the Collective Conversion of Planned Orders: Initial Screen, make the following entries:


Planning Plant Plant 1 (1000)

Production Plant Plant 1 (1000) Optional

Production Scheduler YB2 Optional

Order type YBM2



You should use Production Scheduler (together with production plant) and Opening Date Range to limit the selection. Planned Orders may be firmed if immediate conversion is not required by using transaction MD07.

3. Choose Execute.4. Select the planned orders as noted from the multilevel order report for conversion.

Choose Convert. Make a note of the process order number(s): _________.

ResultThe system generated process order(s).

It is possible to change order quantities (such as merging the quantities of 2 planned orders into one process order. You may then delete the obsolete planned orders from the selection list before executing order conversion. You will need to rerun MRP in order to delete the obsolete planned orders from the database (be aware that the planned orders then must not be firmed, otherwise MRP would leave them untouched).

2. Checking Material Availability – Missing Parts List

UseThis activity allows you to collectively check availability for your process orders.



SAP ECC menu Logistics Production Process Process Order Reporting Missing Parts Info System

Transaction code CO24




Business role menu Production Evaluation Reports MissingPartsInfoSyst

2. On the MissingPartsInfoSyst screen, make the following entries:



Material Optional

Production Scheduler

YB2 Optional



Layout 000000000001 Standard Layout Material View

You should use Production Scheduler (together with production plant) and Opening Date Range to limit the selection. Planned Orders may be firmed if immediate conversion is not required by using transaction MD07.

3. Choose Execute.4. Optional: adapt your layout to additionally show the fields withdrawal Qty and Shortage

Qty.5. Select a line, choose Environment and either

● stock requirements list● stock overview● backorder processing● availability overview● change order

ResultMaterial availability is checked for all relevant process orders within your responsibility area. You may then request, for example, the purchasing department for procurement options.

3. Material Staging for Production

UseThis activity pulls the materials required for the process order from the warehouse storage location to the production storage location.

The materials required are located in the available stock of the warehouse storage location.

In case that there is enough material in the shop floor storage location (1020) or if the requirement date is not yet reached, material staging is not possible.



SAP ECC menu Logistics Production Shop Floor Control Goods Movements Material Staging Pull List

Transaction code MF60


Business role Shop Floor Specialist

(SAP_NBPR_SHOPFLOOR-S)

Business role menu Shop Floor Process Order Processing Material Staging for Planned Orders

2. On the Initial Screen, choose Stor.loc.level.



3. On the Initial Screen, enter your plant and in Selection period for reqmts the date when the materials in the orders are required or later.

4. Choose the Production/process orders tab page.5. Make the following entries:


Production scheduler YB2 Optional

Order <Order number> Optional

Selection period for reqmts.

Leave blank if necessary.

Replenishment storage location

Storage location (1050)

6. Choose Execute.7. On the next screen, choose Select all (at the bottom of the screen).8. Choose Create Replenish. Proposals.9. At the top of the screen, choose Replenishment Elements.10. At the bottom of the screen, choose Select all.11. At the bottom of the screen, choose Batch/Stck Determination.

The Replenishment storage location is found automatically during batch determination, via stock determination rule (maintained in material master MRP2 view). This should be the same storage location as used in the Purchase Order item.

12. On the Batch Determination MM: Select Batches screen, select your batch and choose Copy.

13. At the bottom of the screen, choose again Select all.14. Choose Stage.15. Choose Save.

ResultThe system transfers the materials (material document) from the component storage location to the manufacturing storage location.

4. Multilevel Order Report

UseThis activity generates a worklist for process orders, components and operations, with user-specific selection and layout settings.



SAP ECC menu Logistics Production - Process Process Order Reporting Order Information System Process Order Information System

Transaction code COOISPI






Business role menu Shop Floor Process Order Processing Process Order Information System

2. On the Process Order Information System screen, make the following entries:


List PPIOH000 Order Headers

Select one of the options.

Layout 000000000002 Select one of the options.

Production plant Plant 1 (1000)

Order type YBM2 Optional

Production scheduler YB2 Optional

Sys. status CNF (exclude) Allows selection of all orders that require physical processing

Sys. Status TECO (exclude) Allows selection of all orders that require physical processing

Basic start date current date

Basic start date to end of this week

Using the layout selection within the selection screen you can access the required lists, such as order header, components lists or operations list. Within the report you may download or print the list. Layout settings can be made user-specific, allowing personalized list views.

3. Choose Execute.

Result



You have generated a work list your process orders. If any process orders still have the status Material shortage (MSPT) you can edit these orders and check the material availability (ATP) manually.

5. Goods Issue of Batch-Managed Components

UseThe withdrawing of the raw materials is used for the process order. This can be done by using picking list or manually goods issue.

If the material is set for backflush (in material master or resource), the withdrawing is done automatically after you confirm the operation or the whole order. Backflushing should not be used for batch-managed components (in order to ensure that the physically picked and consumed batch is the same as the recorded batch).

1. Picking Components (Picking List)

UseThe released process order is now ready for picking. All materials that have been moved to the production storage location can be issued to the process order using the pick list.

PrerequisitesEnsure that sufficient material is available in the production storage location. You can check this using transaction MMBE or the missing parts list (CO24, step 4.4.2).



SAP ECC menu Logistics Production - Process Process Order Environment Material Movement Picking

Transaction code COIK




Business role menu Shop Floor Process Order Processing Picking list

2. On the Picking List: Initial Screen, make the following entries:


Profile Standard pick profile 000002

Process order

Order number of the process order to be picked

Enter your order number. Optional



Plant Production plant Plant 1 (1000)

Storage location

Production storage location

Shop floor storage location (1020)

Basic start date

Current date

Basic start date to

Current date + 1

3. Choose Execute.4. Select the relevant reservations and choose Picking. A list of all the selected

reservations is displayed.5. Select the picking lines and choose Batch Determination.

If during batch determination only part of the required quantities is found to be available, the unconfirmed quantity will remain as open line item within the picking list. You should then delete the line item from the picking list prior to saving, as this line item cannot be posted.

6. On the Batch Determination MM: Select Batches screen (NWBC: Picking List), select your batch and choose Copy.

7. Choose Save to post the goods movements.8. Choose Back to return to the SAP Easy Access screen.

ResultThe goods movements have been posted.

2. Goods Issue Manually (Instead of Picking List)



SAP ECC menu Logistics Materials Management Inventory Management Goods Movement Goods Issue (MIGO)

Transaction code MIGO




Business role menu Warehouse Management Consumption and Transfers Other Goods Movement

2. On the Goods Receipt Purchase Order screen (NWBC: Goods Issue Order screen), make the following entries:




Action Goods issue

Reference Order

Order number <Process order number> From previous steps

3. Confirm your entries with Enter.4. Ensure that detail data is not expanded. For each item shown, select OK.5. Select Stock determination for each item. The batch determination is processed in the

background.6. On the Batch Determination MM: Select Batches screen (NWBC: Picking List), select

your batch and choose Copy.7. Choose Check.8. Choose Save.

ResultThe goods movements have been posted.

6. Posting Goods Receipt for Process Order

UseThe purpose of this activity is to post the goods receipt for the process order. You may post goods receipt for the total quantity, but usually already partial quantities of the products are required for further processing, such as consumption for further production or subsequent deliveries for sales orders.



SAP ECC menu Logistics Materials Management Inventory Management Goods Movement Goods Issue (MIGO)

Transaction code MIGO

2. On the Goods Receipt Purchase Order screen, make the following entries:


Action Goods Receipt 1st top-left frame

Reference Order 2nd top-left frame

OrderThe process order number you noted before

Document date Default



Posting date Default

3. Confirm your entries with Enter.4. Choose the Quantity tab and correct the quantity according to the physical quantity

received.5. Set the Delivery Completed Indicator for 2 set if you don’t expect further GR postings for

the given order.6. Maintain the production date if you post GR for your finished product.

The production date is used in order to calculate shelf life expiration date, as maintained in material master (plant storage view).

7. Set the Item OK indicator.8. Choose Post. The system displays the message: Material document 500xxxxxxx posted.9. Choose Back to return to the SAP Easy Access screen.




Business role menu Warehouse Management Consumption and Transfer Other Goods Movement

1. On the Goods Receipt Order screen, make the following entries:


Action Goods Receipt 1st top-left frame

Reference Order 2nd top-left frame

OrderThe process order number you noted before

Document date Default

Posting date Default

2. Confirm your entries with Enter.3. Choose the Quantity tab and correct the quantity according to the physical quantity

received.4. Set the Delivery Completed Indicator for 2 set if you don’t expect further GR postings for

the given order.5. Maintain the production date if you post GR for your finished product.

The production date is used in order to calculate shelf life expiration date, as maintained in material master (plant storage view).

6. Set the Item OK indicator.7. Choose Post. The system displays the message: Material document 500xxxxxxx posted.



ResultThe goods movements have been posted. The batch number has been created automatically during the posting. Production date and shelf life expiration date are recorded within the batch master of the finished product.

7. Confirmation of Production after Goods Receipt Posting

UseIn process industry, GR and GI postings are usually done immediately at the physical movements of the materials in order to ensure batch traceability and data consistency. Order confirmations are done at shift end or day end (with the process orders covering the shift or day production run). The sum of the GR quantity for the given order is then recorded within the confirmation, as well as scrap quantities (optional). The time ticket confirmation allows to record either the default times for machine and labor usage, or record actual times in case of major deviations. If no major deviations occurred, only the last phase needs to be confirmed. Via milestone confirmation all prior phases will then be confirmed automatically.

PrerequisitesThe goods receipt posting for the order product (Finished Product PI (F29) or Semi finished Product PI (S24) has been done in the previous step, the total quantity has been recorded.



SAP ECC menu Logistics Production- Process Process Order Confirmation Enter for Phase Time ticket

Transaction code COR6N




Business role menu Shop Floor Process Order Processing Enter Time Ticket for Process Order

2. On the Enter time ticket for process order screen, make the following entries:


Order The process order number

Phase./

ActivityThe last operation number. For example, 0040.

Optional. If not entered, automatically the last phase default

Confirm. type Final confirmation Default



Clear open reservations

XDefault

3. Confirm your entries with Enter.4. In the Yield field, enter the amount you want to confirm (same quantity as your prior GR

quantity)

If you want to check your backflushed components, continue with step 4.4.8 before saving the confirmation entries.

5. Save your entries.6. Choose Back to return to the SAP Easy Access screen.

ResultThe final confirmation of the last operation has been carried out. Costs and activity quantities have been recalculated in proportion to the yield quantity.

8. Goods Issue for Backflushed Components during Confirmation

UsePackaging materials may not necessarily be batch-managed, and therefore may be issued automatically through order confirmation.

This step is only required for the finished good (F29)

PrerequisitesThe goods receipt posting for the order product (Finished Product PI (F29) has been done in the previous step, the total quantity has been recorded. Tasks 1 to 4 of step Confirmation of Production after Goods Receipt Posting have been performed.

Procedure1. In the Yield field of transaction COR6N, you have already entered the amount you want

to confirm (same quantity as your prior GR quantity).2. Choose Goods Movements.3. Check the material entries and quantities.4. Save your entries.5. Choose Back to return to the SAP Easy Access screen.

ResultThe final confirmation of the last operation has been carried out. Backflushed components are issued with the confirmation posting automatically (packaging material (R15) within the confirmation of orders for Finished Product PI (F29).

6. Follow-up ProcessesYou have finished all activities that are part of the business process described in this document.

To accomplish subsequent activities of this business process, carry out the process steps described in one or more of the following scenarios, using the master data from this document.

Period End Closing “General” Plant (181) (Optional)

© SAP AG of 33


UseIn this activity, you perform the period end financial accounting activities for the plant.

These are executed collectively as a part of month-end closing. For more information on the month-end closing procedure, see the Business Process Documentation for Period end closing "general" Plant.

Note that month-end closing can only be executed once a month.

7. Appendix

1. Reversal of Process StepsIn the following section, you can find the most common reversal steps, which you can take to reverse some of the activities described in this document.

Create Independent Requirements

Transaction code (SAP GUI) MD61

Reversal: Change Independent Requirements

Transaction code (SAP GUI) MD62



Business role menu Production Production Planning Demand Management Change Planned Indep. Requirements

Comment Delete line items in planning table. MRP has to be rerun to correct dependent requirements

Convert Planned Order to Process Order

Transaction code (SAP GUI) COR8

Reversal: Change Process Order – Restrict Processing

Transaction code (SAP GUI) COR2





Business role menu Production Shopfloor Control Process Order Change Process Order

Comment It is not possible to delete process orders directly (deletion may only occur via archiving). Instead, further processing is restricted, so that goods movements and cost postings with reference to the restricted orders is not longer allowed

Select Technical completion if costs have already been posted with order reference, in order to allow further order settlement. Selection of Lock will not only block logistics movements but also order settlement. Final order closure is only possible if the order balance is zero.

Material Staging for Order

Transaction code (SAP GUI) MF60

Reversal: Cancel material document

Transaction code (SAP GUI) MBST



Business role menu Warehouse Management Consumption and Transfers Cancel Material Document

Comment The material posting of the material document is reversed. The original document remains in the system’s database

Process Goods Issue of batch-managed components

Transaction code (SAP GUI) COIK, MIGO









Goods Receipt from Production

Transaction code (SAP GUI) MIGO







Confirmation of Production after Goods Receipt Posting

Transaction code (SAP GUI) COR6N

Reversal: Cancel process order confirmation

Transaction code (SAP GUI) CORS



Business role menu Shop Floor Process Order Processing Cancel Process Order Confirmation

Comment If backflushing was used for components issue, the



relevant material movement is cancelled as well.

Goods Issue for backflushed components during confirmation

Transaction code (SAP GUI) COR6N

Reversal: Cancel process order confirmation

Transaction code (SAP GUI) CORS



Business role menu Shop Floor Process Order Processing Cancel Process Order Confirmation

Comment

2. SAP ERP Reports

UseThe table below lists the reports that you can use to obtain additional information on this business process.

You can find detailed descriptions of the individual reports in the following BPD documents, which provide a comprehensive compilation of all important reports:

● Financial Accounting: SAP ERP Reporting for Accounting (221)● Logistics Processes: SAP ERP Reports for Logistics (222)

Note that the descriptions of some reports that are an indispensable part of the process flow may be located directly in the section where they belong.

Reports

Report title Transaction code

NWBC Business Role

Business Role Menu

Comment

Capacity Planning CM01 Production Supervisor

Production Evaluation Capacity Overview

The capacity evaluation is displayed.

Missing Parts Info CO24 Production Production A list of missing



System Supervisor Worklist parts.

Process Order Information System

COOISPI


Production Worklist

A list of all process orders.

MRP List MD05 Production Planner

Production Evaluations MRP List Individual Display

The stock/requirements situation at the time of the last planning run.

Stock Overview MMBE Warehouse Manager

Warehouse Management Inventory Control Environment Stock Overview

A list of stock is displayed.
