tscm42_en_col92_fv_inst_a4.pdf

TSCM42TSCM42 Planning & Manufacturing

IISAP SCM

Date

Training Center

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Education Website

Instructor HandbookCourse Version: 92Course Duration: 10 Day(s)Material Number: 50095466Owner: Hochadel Bernd (D021005)

An SAP Compass course - use it to learn, reference it for work

Copyright

Copyright 2009 SAP AG. All rights reserved.

No part of this publication may be reproduced or transmitted in any form or for any purposewithout the express permission of SAP AG. The information contained herein may be changedwithout prior notice.

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THESE MATERIALS ARE PROVIDED BY SAP ON AN "AS IS" BASIS, AND SAP EXPRESSLYDISCLAIMS ANY AND ALL WARRANTIES, EXPRESS OR APPLIED, INCLUDINGWITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR APARTICULAR PURPOSE, WITH RESPECT TO THESE MATERIALS AND THE SERVICE,INFORMATION, TEXT, GRAPHICS, LINKS, OR ANY OTHER MATERIALS AND PRODUCTSCONTAINED HEREIN. IN NO EVENT SHALL SAP BE LIABLE FOR ANY DIRECT,INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES OF ANYKIND WHATSOEVER, INCLUDING WITHOUT LIMITATION LOST REVENUES OR LOSTPROFITS, WHICH MAY RESULT FROM THE USE OF THESE MATERIALS OR INCLUDEDSOFTWARE COMPONENTS.

g20096152440

About This HandbookThis handbook is intended to complement the instructor-led presentation of thiscourse, and serve as a source of reference. It is not suitable for self-study.

Typographic ConventionsAmerican English is the standard used in this handbook. The followingtypographic conventions are also used.

Type Style Description

Example text Words or characters that appear on the screen. Theseinclude field names, screen titles, pushbuttons as wellas menu names, paths, and options.

Also used for cross-references to other documentationboth internal and external.

Example text Emphasized words or phrases in body text, titles ofgraphics, and tables

EXAMPLE TEXT Names of elements in the system. These includereport names, program names, transaction codes, tablenames, and individual key words of a programminglanguage, when surrounded by body text, for exampleSELECT and INCLUDE.

Example text Screen output. This includes file and directory namesand their paths, messages, names of variables andparameters, and passages of the source text of aprogram.

Example text Exact user entry. These are words and characters thatyou enter in the system exactly as they appear in thedocumentation.

Variable user entry. Pointed brackets indicate that youreplace these words and characters with appropriateentries.

2009 2009 SAP AG. All rights reserved. iii

About This Handbook TSCM42

Icons in Body TextThe following icons are used in this handbook.

Icon Meaning

For more information, tips, or background

Note or further explanation of previous point

Exception or caution

Procedures

Indicates that the item is displayed in the instructorspresentation.

iv 2009 SAP AG. All rights reserved. 2009

ContentsCourse Overview ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Course Goals .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiiCourse Objectives ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Unit 1: Introduction..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Overview of the Training for Solution Consultant SCM Planning &Manufacturing... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Production Types of the SAP ERP and SAP SCM Applications ..7

Unit 2: Order-Controlled Production with Process Orders..... 21Order-Controlled Production with Process Orders .. . . . . . . . . . . . . . 22Elements, Functions, and Processing of a Process Order .. . . . . 40

Unit 3: Repetitive Manufacturing..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Characteristics of Repetitive Manufacturing.. . . . . . . . . . . . . . . . . . . . . . 90Functions and Process Steps in Repetitive Manufacturing.. . . .109

Unit 4: Kanban..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Features of the KANBAN Procedure .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .150The KANBAN Procedure.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

Unit 5: Capacity Requirements Planning (ERP) ..... . . . . . . . . . . . . 171Capacity Planning Environment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173Capacity Evaluation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180Capacity Leveling in Table Form.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198Available Capacity . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214Capacity Leveling in Graphical Form.... . . . . . . . . . . . . . . . . . . . . . . . . . .220

Appendix 1: Summary ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Appendix 2: References ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Appendix 3: Detailed Functions of Capacity RequirementsPlanning ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

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Contents TSCM42

vi 2009 SAP AG. All rights reserved. 2009

Course OverviewProduction is part of the applications SAP ERP (Enterprise Resource Planning)and SAP SCM (Supply Chain Management) in the SAP Business Suite. You canuse this to manage all the production activities within your supply chain in oneintegrated system, from planning through execution to analysis. The focus of thiscourse is execution. The following topics are dealt with in particular:

Order-Controlled Production with Production Orders

This section is performed with the original files of customer training courseSCM310.

Order-Controlled Production with Process Orders Repetitive manufacturing KANBAN Capacity Requirements Planning (ERP)

Information on SAP software components

The information in this course is based on the following SAP software componentsand releases:

SAP ECC Enterprise Central Component 6.0, EhP4 SAP SCM Supply Chain Management 7.0

Target AudienceThis course is intended for the following audiences:

Application consultants responsible for the implementation of shop floorcontrol as part of the applications of SAP Business Suite

Course PrerequisitesRequired Knowledge

SAP125 SAP Navigation (E-Learning) TSCM40 Planning & Manufacturing I SM001 Introduction to the SAP Solution Manager Additional e-learning products (see graphic 1)

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Course Overview TSCM42

Recommended Knowledge

SAPSCM: SCM Overview PLM100 Lifecycle Data Management SCM100 Planning Overview (ERP) SCM200 Planning Overview (SCM)

Course Duration DetailsUnit 1: IntroductionOverview of the Training for Solution ConsultantSCM Planning & Manufacturing 20 Minutes

Production Types of the SAP ERP and SAP SCMApplications 60 Minutes

Unit 2: Order-Controlled Production with Process OrdersOrder-Controlled Production with Process Orders 70 MinutesExercise 1: Master Data of Order-ControlledProduction with Process Orders 30 Minutes

Elements, Functions, and Processing of a ProcessOrder 145 MinutesExercise 2: Integration with Planning; ProcessOrder Creation with Planned Orders 30 Minutes

Exercise 3: Process Order Release; Processing anOrder with a PI Sheet 30 Minutes

Unit 3: Repetitive ManufacturingCharacteristics of Repetitive Manufacturing 40 MinutesExercise 4: Master Data - Optional 20 MinutesFunctions and Process Steps in RepetitiveManufacturing 115 MinutesExercise 5: Integration with Production Planningand MRP in the ECC System 20 Minutes

Exercise 6: Line Loading Planning in the ECCSystem 20 Minutes

Exercise 7: Material Staging and Backflush 20 Minutes

Unit 4: KanbanFeatures of the KANBAN Procedure 15 MinutesThe KANBAN Procedure 20 Minutes

Unit 5: Capacity Requirements Planning (ERP)Capacity Planning Environment 60 MinutesCapacity Evaluation 45 MinutesExercise 8: Standard Overview 15 MinutesCapacity Leveling in Table Form 120 MinutesExercise 9: Tabular Capacity Planning Table 30 MinutesAvailable Capacity 120 Minutes

viii 2009 SAP AG. All rights reserved. 2009

TSCM42 Course Overview

Capacity Leveling in Graphical Form 45 MinutesExercise 10: Planning Strategies 20 Minutes

Course GoalsThis course will prepare you to:

Understand the positioning, integration, and functions of the production areawithin the SAP ERP (Enterprise Resource Planning) and SAP SCM (SupplyChain Management) solutions

Get an overview of the supported production types and CapacityRequirements Planning (ERP)

Course ObjectivesAfter completing this course, you will be able to:

Describe basic shop floor control procedures and functions and understandsimple scenarios in the SAP System

Use capacity planning functions for your consulting activities

SAP Software Component InformationThe information in this course pertains to the following SAP Software Componentsand releases:

SAP ERP Central Component 6.0 SAP SCM 7.0

LOCATION FOR THE INFORMATION XML-BASED TRAININGMATERIAL. INSTRUCTOR HANDBOOK In addition to the InstructorHandbook for XML-based training material, the most important recommendedinformation is placed in a separate Instructor guide, TSCM42 Trainerguide,which you can find at http://service.sap.com/curr-info RECOMMENDEDINFORMATION

HINTS ON PREPARING THIS COURSE

Remember to check for additional information not published after the coursematerial was finally released. For latest information or course updates seeadditional Instructor Guide/System Setup Guide or Trouble Shooting Guide onSAP Service Marketplace under the alias

http://service.sap.com/curr-info

TRAINING SYSTEM

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Your training systems will be available and accessible on Sunday evening (CETtime zone) in the week the training takes place. Do not use the system or prepareyour course before that time. The system may still be in use by another courseor in the refresh procedures of the IT preparation for your course. If you need atest/prep. system before your course takes place, see details under the sectionTest/Prep. System.

MATERIAL REQUIRED FOR PARTICIPANTS

In this course the following training material is necessary:

For the first course week: SCM310 Coll. 92 For the second course week: TSCM42 Coll. 92

DATA REQUIRED

For this TSCM42 course you need a training landscape consisting of an SAPERP 6.0 system with enhancement package 4 and the corresponding SAP SCM7.0 system. This means that CIF integration must exist and be active betweenboth systems.

Test/Preparation System

There are test/prep systems for most SAP courses. You can find the necessaryinformation at http://service.sap.com/curr-info. If you cannot access this site,ask the responsible education coordinator (the person who send you this guide)to provide you with the relevant information. If no test/preparation system existsfor the course, but testing or preparation is essential, let the education departmentorder or book a system via a CSS ticket at least one week before the training.Please note that test/preparation systems must not be used for training without thepermission of KPS. An access violation fee will be charged.

Using Training WTS farm

Nearly all SAP courses are designed to be taught via SAP Training WindowTerminal Server Farms (WTS farms) so that customers can be trained on-site(on-site training). Unless the course restrictions specify another WTS farm or theuse of the local PC front end, always use the "Common Training" WTS farm fortraining. Only use SAP software on the local PC front end in SAP-owned training

x 2009 SAP AG. All rights reserved. 2009

TSCM42 Course Overview

centers that have good network bandwidth connections. Using SAP software onthe local PC front end restricts the training support to the local IT support. Theglobal training support can only support training courses via Training WTS farms.

Training at SAP training centers/internal SAP training

The internal connectivity to the training WTS farms can only be used insidethe SAP network infrastructure.

To connect to the training WTS farm use http://wts.wdf.sap.corp:1080.Choose a region (AMERICAS, EMEA, or APJ). Select the "Training Zone"menu. Connect to "Common Training" if no other WTS farm is specified forthe training course.

Customer on-site training / third party training center

Customer Onsite training can only connect to SAP training WTS farm viathe SAP Citrix Secure Gateway (SAP CSG). You therefore need a CSG-UserID. The User ID needs to have been created by the education department intime for the training. The data (User ID and password) are delivered to youby the education department. The instructor and participants use the samededicated CSG user ID and password for training.

To connect to the training WTS farm, use http://mywts.sap.com. Choose aregion (AMERICAS, EMEA, or APJ).

Enter the CSG user ID and password, and log on. Select the Training icon.Connect to "Common Training" if no other WTS farm is specified for thetraining course.

USER ID AND PASSWORDS FOR THE COURSE

Training with Reference User IDs:To create the participants users (and, if necessary, your instructoruser) directly before the course starts, log on to both training systemswith the user Training. The monthly changed password should bedelivered by your education department in the training informationemail/documentation. The standard format for User IDs is the CourseID (here: TSCM42), followed by the group number (here: ## beingthe group number 00 up to max. 30). The user ID will thus beTSCM42-##. The initial password is Fertigung. Use transactionZUSR to copy these User IDs from the reference User ID (e.g. fromyour own user or from the user TSCM42MUSTER).

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ADDITIONAL PREPARATION IN THE SYSTEM

Example ABAPsnone

CATTs/eCATTSThere is a CATT for the course. This is executed centrally.

Switching on/off table locking in SAP systemsDo not switch off table locking in this course.

TECHNICAL HINTS

Further activities to be carried out before the course commences:

Take a look at the separate Instructor Guide TSCM42 Trainerguide

xii 2009 SAP AG. All rights reserved. 2009

Unit 11 Introduction

Please use a separate, detailed Trainer Guide, which you can find on the SAPCorporate Portal.

Unit OverviewProduction Types of the SAP ERP and SAP SCM Applications

In this unit, you will learn about the production types within the SAP BusinessSuite.

Unit ObjectivesAfter completing this unit, you will be able to:

Obtain an overview of the scope of the training Name the production types supported in the SAP Business Suite.

Unit ContentsLesson: Overview of the Training for Solution Consultant SCM Planning &Manufacturing ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Lesson: Production Types of the SAP ERP and SAP SCM Applications ..7

2009 2009 SAP AG. All rights reserved. 1

Unit 1: Introduction TSCM42

Lesson:2

Overview of the Training for Solution Consultant SCMPlanning & ManufacturingLesson Duration: 20 Minutes

Lesson OverviewOverview of the Training for Solution Consultant SCM Planning & Manufacturing

Lesson ObjectivesAfter completing this lesson, you will be able to:

Obtain an overview of the scope of the training

Business ExampleNone

Basic TrainingThe training courses TSCM40 (Planning/Manufacturing I) and TSCM42(Planning/Manufacturing II (including case study)) provide the participants withknowledge concerning the business processes of planning and manufacturing ina basic training geared towards manufacturing companies.

In the training course TSCM40 (Planning/Manufacturing I), you learn aboutmaster data required for production (material masters, bills of material, workcenters, routings, production resources/tools), including master data management,as well as about concepts and business processes of different planning areas. Thetraining course deals with the processes of production planning using materialrequirements planning (PP-MRPmodule) based on a number of examples, as wellas the different planning strategies for creating a product plan. The course alsodemonstrates evaluation methods for valuating the planning results.

The training course TSCM42 (Planning/Manufacturing II (including casestudy)) familiarizes you with different options for controlling the production.This includes order-based production with production orders or process orders,repetitive manufacturing, Kanban and preproduction of production lots. Theseoptions provide effective support for the complete manufacturing processincluding the process steps material staging, sequencing, creation of shop floor


TSCM42 Lesson: Overview of the Training for Solution Consultant SCMPlanning & Manufacturing

papers, confirmations, backflushing, goods receipt, and settlement of productionactivities. The focus is on production order management. An overview isalso provided of other options.

The training course also contains a case study, which allows you to make practicaluse of the knowledge you acquired by configuring specified integrated businessprocesses. At the end of the course, participants take an exam for certification as aSolution Consultant SCM - Planning/Manufacturing with SAP ERP 2005.

The following diagram provides an overview of the scope of the training.

Figure 1: Basic Training: Consultant Profile SAP SCM - Planning &Manufacturing (for New Consultants)

Alternative Project Team Training

The training material of the Consultant Academy is largely based on the relevantstandard training, but is supplemented by topics that are relevant for consultants.The following table shows which topics were taken from the standard training andwhich topics are discussed additionally:

Consultant Academy TrainingCourse

Course Content

TSCM40 (Planning/ManufacturingI)

2 days PLM110 (Basic Data, Part 1)

3 days PLM111 (Basic Data, Part 2)



5 days SCM240 (Production Planning(ERP))

TSCM42 (Planning/ManufacturingII (incl. Case Study))

4.5 days SCM310 (Production Orders)

0.5 days KANBAN from SCM300(Production Overview)1 day SCM360 (Capacity Planning(ERP))1 day Repetitive Manufacturing andProcess Manufacturing from SCM3002.5 days Integrated Case Study3 hours Certification Exam

Advanced Training

Advanced training is geared towards consultants who have already participatedin the detailed training for SCM - Planning/Manufacturing, or who have theequivalent skills and want to increase their knowledge of and specialize inthe SCM(APO) module in the areas of Demand Planning (DP) and SupplyPlanning (SNP), and obtain certification.

Advanced training involves participation in the customer training coursesSCM220 (Demand Planning) and SCM230 (Supply Network Planning (SNP)).See also the current training program of SAP customer training.

Figure 2: Advanced Training: Consultant Profile SAP SCM - Planning

Additional Information

The parts Basic Data, Part 1 and Part 2 (TSCM40) and Production Orders(TSCM42) are carried out with the original training materials of the relevantstandard courses.

The e-learning courses specified in figure 1 serve as the basis for the training.


TSCM42 Lesson: Overview of the Training for Solution Consultant SCMPlanning & Manufacturing

Facilitated Discussion

Discussion QuestionsUse the following questions to engage the participants in the discussion. Feel freeto use your own additional questions.



Lesson Summary

You should now be able to: Obtain an overview of the scope of the training


TSCM42 Lesson: Production Types of the SAP ERP and SAP SCM Applications

Lesson:6

Production Types of the SAP ERP and SAP SCMApplicationsLesson Duration: 60 Minutes

Lesson OverviewIn this lesson, you learn about the production types that are supported withinthe SAP Business Suite.


Name the production types supported in the SAP Business Suite.

For demonstrations and instructor notes, see the instructor guide on the SAPCorporate Portal.

Business ExampleA company implements the SAP Business Suite. As a consultant, you are either amember of the project team responsible for implementing the shop floor controlfunctions or you are in the production department. You use various scenarios togain an overview of the options and functions of the supported production typesand capacity requirements planning (ERP).



Overview of SAP Applications

Figure 3: SAP ERP Application Overview

SAP offers an SAP Business Suite, consisting of several applications, as part ofits long-term product strategy.

The Enterprise Resource Planning (ERP) application is a comprehensiveapplication that allows a company to efficiently plan, manage, and check complexdelivery, procurement, and production networks.

This application supports synchronized and close interaction between all thedepartments (and people) involved in a supply chain.

Customers, sales, production planning, manufacturing, warehouse management,purchasing, and vendors are all included in this complete solution.

The SAP ERP application covers several areas (see above).

For more information about the individual components of the SAP ERPapplication, see

http://www.sap.com/solutions/businessmaps/solutionmaps/

and cross-industry business maps.



Figure 4: SAP SCM Application Overview

SAP Supply Chain Management (SCM) is a comprehensive application thatallows a company to plan, realize, and monitor complex delivery, procurement,and product relationships (supply chains) efficiently.

This application supports a synchronized and close interaction between alldepartments (and people) involved in a logistics chain.

Customers, sales, production planning, manufacturing, warehouse management,purchasing, and vendors are all included in this complete solution.

The processing of cross-company or collaborative planning and procurementprocesses, which also allow a connection to open marketplaces, is a specialfeature of this solution.

The SAP SCM application covers several areas (see above).

For more information about the individual components of the SAP SCMapplication, see

http://www.sap.com/solutions/businessmaps/solutionmaps/

and cross-industry business maps.



Figure 5: SAP Components

For the most part, in-house production is realized with the SAP ECC systemcomponent:

Advanced Planning and Optimization (APO) in SAP SCM provides considerablyenhanced planning tools: With Supply Network Collaboration (SNC) itoffers a tool for cross-system collaboration between companies, with ExtendedWarehouse Management (EWM) an enhanced warehouse management system,and with Event Management (EM) a tool to tracking events.

SNC, EWM, and EM are also suitable for use as standalone systems.

SAP BW (Business Information Warehouse) is used to store data separatelyacross the company group for variable evaluations.

SAP CRM offers more comprehensive sales order management options that thoseprovided in SAP ECC.

Interfaces that integrate ECC with SCM, BW, or CRM are provided with anappropriate plug-in (integrated in SAP ECC).

The interface between ECC and SCM (APO) is called the Core Interface (CIF).

Several interfaces (PP-PDC, PI-PCS, SAP ODA) and SAP ManufacturingIntegration and Intelligence (SAP MII) software are available to integrateproduction with process-based command and control systems.

The cross-system use of multiple system components and their applications canbe simplified by giving end users role-based UIs (user interfaces). For the roleof production scheduler you can use the SAP Enterprise Portal or the SAPNetWeaver Business Client.



Figure 6: Process Integration and Intelligent Architecture

With SAP MII, SAP provides an adaptive manufacturing application forproduction. This composite application SAP xApp Manufacturing Integrationand Intelligence (SAP MII) gives manufacturing companies greater flexibility byimproving the link between the SAP ERP application and the production processlevel, as well as providing employees with realtime information.

You can implement SAPMII in a plant very quickly, thus extending the functionsof the SAP NetWeaver technology platform to production too.

You can improve how you organize production, external procurement, andwarehouse stock from a business perspective and adjust them dynamically inresponse to unexpected changes. Manufacturing companies are thus able torespond to realtime information from production immediately, enabling them towork faster and at lower cost. The application makes it easier for you to arrangethe production processes as well as the corresponding areas (plant maintenance,quality management) more effectively.

SAP MII provides standardized, preconfigured connectors to enable realtimedata integration in Manufacturing Execution Systems (MES) and SCADASystems (Supervisory Control and Data Acquisition).

You can run realtime analyses and display the results in browser and role-baseddashboards. They provide important information for checking and supportingdecision-making, such as warnings, job lists, analyses, reports, and realtimemessages about production variance.

You can incorporate this information in role-based enterprise portals.



Preconfigured dashboards are currently available for the roles of plant manager,production scheduler, quality officer, and maintenance manager.

You can find information about MII in the Internet underhttp://www.sdn.sap.com/irj/sdn/bpx-manufacturing

Figure 7: Production Scheduler in the Enterprise Portal

This slide shows an example of the Overview page for a production schedulersportal.

For the role of production scheduler, the Enterprise Portal allows you toactively process and track production orders, process orders, and other objects.

The figure above shows an example of the Overview page for a productionschedulers portal.

You can see the worklist that the production scheduler has to process or checkat the bottom left (production orders, quality notifications, inspection lots,malfunction reports, and maintenance orders).

The following functions are possible: Change, display, and confirm orders.You can incorporate and execute any transactions and reports you wish.

You can integrate any pages and iViews into the portal with ease.

In order to use the portal, all you have to do is install an additional portal server.The software is included in SAP NetWeaver.

If you want to learn about Enterprise Portal technology, you can attend the SAPtraining courses SAPEP and EP200.



You can find information about the Enterprise Portal and roles in the Internet underhttp://www.sdn.sap.com/irj/sdn/bpx-manufacturing

Production TypesDepending on the manufacturing process, product complexity, stability ofproduction, and other criteria, a company has various requirements with regardto shop floor control.

For this reason, SAP ERP und SAP SCM support a variety of production types.

Figure 8: Production Types (1)



Figure 9: Production Types (2)



Facilitated DiscussionAs part of the round of introductions, you can ask the participants about therequirements of their company or project.




Lesson Summary

You should now be able to: Name the production types supported in the SAP Business Suite.


TSCM42 Unit Summary

Unit SummaryYou should now be able to: Obtain an overview of the scope of the training Name the production types supported in the SAP Business Suite.


Unit Summary TSCM42


TSCM42 Test Your Knowledge

15Test Your Knowledge

1. Name the production types that are supported within the SAP Business Suite.


Test Your Knowledge TSCM42

16Answers

1. Name the production types that are supported within the SAP Business Suite.

Answer:

Order-related production with production order Order-related production with process order Repetitive manufacturing:

Period- and quantity-oriented production Not order-related

Kanban:

Replenishment-controlled using stock transfer, externalprocurement, in-house production via self-controlled control cycle

Project-oriented production with production lot


Unit 217 Order-Controlled Production with

Process Orders

To find out how the exercises fit into the course from a timing point of view,see the proposal in the instructor guide.

Unit OverviewIn this unit, you will learn about process order-controlled production.

Unit ObjectivesAfter completing 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

Unit ContentsLesson: Order-Controlled Production with Process Orders ... . . . . . . . . . . . . . 22

Exercise 1: Master Data of Order-Controlled Production with ProcessOrders... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Lesson: Elements, Functions, and Processing of a Process Order.. . . . . . 40Exercise 2: Integration with Planning; Process Order Creation withPlanned Orders .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Exercise 3: Process Order Release; Processing an Order with a PISheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71


Unit 2: Order-Controlled Production with Process Orders TSCM42

Lesson:18

Order-Controlled Production with Process OrdersLesson Duration: 70 Minutes

Lesson OverviewThe following topics are dealt with in this lesson:

Application areas of process orders Process-order-controlled production: Characteristics Cross-application process flow Master data for process orders


Explain the characteristics of order-controlled production with process orders


Business ExampleYour company is a process manufacturing company. You produce order-relatedproducts. You are on the project team for implementing shop floor controlfunctions based on process orders.


TSCM42 Lesson: Order-Controlled Production with Process Orders

Application Areas of Process Orders

Figure 10: Application Areas of Process Orders

Process orders are used in different areas of the process manufacturing industry.

Process orders can be used for various production procedures and identified, forexample, according to the criteria product complexity and product stability.



Process-Order-Controlled Production: Characteristics(1)

Figure 11: Process-Order-Controlled Production: Characteristics (1)

(*) Note:

In process manufacturing, there are usually increased requirements with regard tothe integration of batch management and quality management within the supplychain.




Notes:

The central idea behind process orders corresponds in many ways to the ideabehind production orders. The following basic functions are also supported byproduction orders but are normally used in process manufacturing:

(1) You have to select a production version when you open an order

(2) The materials in process manufacturing are normally managed in batches.There are functions for batch number assignment for the product and for batchdetermination of material components.

(3) After an order is released, control recipes with parameters for the processcontrol level can be generated by the system and sent to an external system orformatted within ECC in as a process instruction (PI) sheet to be processedinteractively on the screen.

Hint: For production orders, the synonyms control instructions (= controlrecipe) and operational method sheet (= PI sheet) are used.




Process management

Process management is the interface between the process orders and the systemsinvolved in process control. Due to its flexible structure, it can be linked tofully automated, partially automated, and manually operated lines. Processmanagement includes communication with the process control level via thePI-PCS interface or PI sheets.

Control recipes from released process orders are sent to process control systemsor formatted as HTML PI sheets in the respective native language in the SAPECC system.

Process messages with actual process data are received from the PI sheet or theprocess control system in return.

Hint: The process control functions are available as of Release ECC 6.0Enhancement Pack 3 for production orders too. The following synonymsexist: Process integration (= process control), control instruction (=control recipe), operational method sheet (= PI sheet).

SAP OPC data access (SAP ODA)

SAP OPC data access (SAP ODA) enables the system to read and write datapoints and events using the OPC server for the ECC system. This function isalso available with production orders.



OPC stands for OLE for Process Control and Openess, Productivity andConnectivity. OPC is a standard that uses COM/DCOM technology to defineinterfaces independent of the manufacturer for use in industry. The OPC standardwas designed especially for the process control level. OPC servers allow accessto various data sources (such as process control systems, programmable logiccontrollers, and temperature sensors) and thus provide process data that can berequested by OPC clients. SAP ECC with the SAP ODA component is an OPCserver and client that can communicate with OPC servers. It makes data exchangebetween applications considerably easier.

OPC clients and OPC servers are currently pc-based systems on which a Microsoftoperating system runs.

You can find further information on the OPC Foundation Web siteshttp://www.opcfoundation.org and www.opceurope.org.

SAP MII

With SAP MII Manufacturing Integration and Intelligence, SAP offers anadaptive manufacturing solution for production. SAP MII gives manufacturingcompanies increased flexibility through improved linking of the SAP ERPsolution to the production process level and by making realtime informationavailable to employees.

You can use SAP MII both in the process order and production order environment.

SAP MII provides standardized, preconfigured connectors to enable realtimedata integration in Manufacturing Execution Systems (MES) and SCADASystems (Supervisory Control and Data Acquisition).

You can run realtime analyses and display the results in browser and role-baseddashboards. They provide important information for checking and supportingdecision-making, such as warnings, job lists, analyses, reports, and realtimemessages about production variance.



Cross-Application Process Flow

Figure 14: Cross-Application Process Flow

Process order management is a central part of a complex process chain startingwith a requirement (planned or customer requirement) and ending with the goodsissue of finished products.

Process order management controls the whole process of in-house productionof products.

Process order execution is integrated with the functions of capacity requirementsplanning, costing, and inventory management. Integration is also provided withbatch management and quality management, interfaces to process control systems,and laboratory information systems.



Master Data for Process Orders

Figure 15: Master Data for Process Orders

Master data is data in the SAP system that remains unchanged over a longperiod of time. It contains information that is required in the same manner overand over again.

The material is the central master record in Logistics. In general, SAP definesa material as a substance or commodity that is bought or sold on a commercialbasis, or is used, consumed, or created in production.

A batch is a uniquely identifiable partial quantity of a material. The batchesof a material are managed in separate stocks. With regard to the productionprocess, a batch is a quantity of a specific material produced during a standardizedproduction run. This quantity, therefore, represents a non-reproducible unit withunique specifications.

The master data for resources describes the means of production in the productionprocess.

A production version determines which alternative BOM is used in combinationwith which master recipe for process order manufacturing.

The master data of themaster recipes describes the non-order-specific productionof one or more materials in a production run.

Material BOMs show the structure of products that are produced in a company.They are usually created and maintained from the master recipe (integratedmaintenance).



Material and Batch

Figure 16: Material and Batch

In different sectors, especially in the process industry, it is necessary to workcontinuously through the logistic quantity and value chain using homogeneouspartial quantities of a material.

In the SAP system, batch master records always depend on material masterrecords. Batches are created for a material.

In general, the data of a material master is valid for all batches assigned to it.By contrast, a batch master record contains data that uniquely identifies thecorresponding batch and characterizes the unit as one that cannot be reproduced.

The characteristic batch specifications are assigned using characteristics from theclassification system in the material master and are inherited by the correspondingbatch master records.

If you want a material to be produced and managed in batches, you have to set thesubject to batch management requirement indicator in the material master record.

A batch master record is usually created by the system in the background forcertain business operations (such as goods receipt). Users can also create batchmaster records directly in master data maintenance.



Batch Management in Supply Chain Management

Figure 17: Batch Management in Supply Chain Management

Batch management is used in all areas of Logistics. A batch can be traced acrossthe whole supply chain, from the receipt of the raw material to processing inproduction and the creation of the final product, all the way to sales and deliveryto the customer.

You can use a batch master record to assign a batch to a material at differentplaces along the supply chain. For example, if the partial quantity of a materialsubject to batch management requirement with certain specifications leaves aproduction process (process order), it is posted to stock with a batch number andcan be uniquely identified there.

If a batch with certain specifications is required in the supply chain, you can usethe batch determination function to enable the system to locate suitable batches instock. In production, for example, batch determination is used in a process orderto find and withdraw suitable material components for the product to be produced.



Demo Scenario: Ice Cream Production in Plant 1100

Figure 18: Demo Scenario: Ice Cream Production in Plant 1100



29 Exercise 1: Master Data ofOrder-Controlled Production withProcess OrdersExercise Duration: 30 Minutes

Exercise ObjectivesAfter completing this exercise, you will be able to: Name the master data that is important for process-order-controlled

production Select production versions in mass maintenance Navigate from mass maintenance for production versions to master recipes Navigate from a master recipe to the relevant BOM (integrated BOM

maintenance)

Business Example

Hint: This exercise is optional.

You are an employee in a company that produces food products and alcoholicbeverages. You are a member of the SAP project team and responsible forimplementing the functions of order-controlled production with process orders.You will first get a general overview of the basic master data.

Next you will display the master data production version, master recipe, andBOM for the product T-FI1## Vanilla ice cream - packaged and becomefamiliar with the structure, basic data and navigation in these master records.

Task 1:

1. First, gain an overview of the menu structure of the production planning andcontrol functions for process industries.

Which menu path takes you to these functions?

2. Name the basic master data for process-order-controlled production

3. Which menu paths take you to the maintenance transactions for materialmaster records, batches, production versions, resources, and master recipes?

Continued on next page



Task 2:Go to mass maintenance for production versions and select the productionversion(s) for the material T-FI1## Vanilla ice cream - packaged in plant 1100.

1. Display the details for production version 0001. Which task list and whichBOM are assigned to each other through the production version?

______________________________________________________

______________________________________________________

For which lot size range and which time period is the production versionvalid?

______________________________________________________

______________________________________________________

2. Navigate from mass maintenance to the master recipe for production version0001.

3. Get an overview of the master recipe structure and the data in the RecipeHeader, Operations, and Materials views.

4. From the Materials master recipe view, navigate to the BOM for materialT-FI1##.

5. Get an overview of the data in the BOM and then go back to the masterrecipe.

6. Exit the master recipe and mass maintenance for production versions.



Solution 1: Master Data ofOrder-Controlled Production withProcess OrdersTask 1:

1. First, gain an overview of the menu structure of the production planning andcontrol functions for process industries.

Which menu path takes you to these functions?

a) SAP Menu Logistics Production - Process (...)

The menus appear for

- Master Data- Production Planning (SOP, Production Planning, MRP)- Shop Floor Control (Process Order, Production

Campaign, Process Planning,Process Management)

- Product Cost Planning

2. Name the basic master data for process-order-controlled production

a) For more information, refer to the page Master Data for the ProcessOrder in your training material.

The basic master data is as follows:

Material and Batch Resource Production Version Master Recipe BOM




3. Which menu paths take you to the maintenance transactions for materialmaster records, batches, production versions, resources, and master recipes?

a) SAP Menu Logistics Production - Process Master Data

Material Master ()

Material Master Batch ()

Production Versions

Resources ()

Master Recipes ()

Task 2:Go to mass maintenance for production versions and select the productionversion(s) for the material T-FI1## Vanilla ice cream - packaged in plant 1100.

1. Display the details for production version 0001. Which task list and whichBOM are assigned to each other through the production version?

______________________________________________________

______________________________________________________

For which lot size range and which time period is the production versionvalid?

______________________________________________________




______________________________________________________

a) SAP Menu Logistics Production - Process Master Data Production Versions

Plant: 1100Material: T-FI1##

Enter

Double-click the row for production version 0001

Lot size from 2000 to 10000 kg

Plan Task List Type: Master Recipe Group: T-ICE## Group Counter: 1BOM Alternative BOM: 1

PlanTask List Type: Master RecipeGroup: T-ICE##Group Counter: 1

BOMAlternative BOM: 1

2. Navigate from mass maintenance to the master recipe for production version0001.

a) Choose Recipe

3. Get an overview of the master recipe structure and the data in the RecipeHeader, Operations, and Materials views.

a) Choose the appropriate tabs to navigate between the views.

4. From the Materials master recipe view, navigate to the BOM for materialT-FI1##.

a) In the Materials view

BOM push button

5. Get an overview of the data in the BOM and then go back to the masterrecipe.

a) To exit the BOM, choose Back (F3).




6. Exit the master recipe and mass maintenance for production versions.

a) To exit the recipe, choose: Exit (Shift+F3)

To exit mass maintenance for production versions, choose Exit (Shift+F3).

Facilitated DiscussionUnderstand application areas and characteristics of shop floor control with processorders




Lesson Summary

You should now be able to: Explain the characteristics of order-controlled production with process orders



Lesson:36

Elements, Functions, and Processing of a ProcessOrderLesson Duration: 145 Minutes

Lesson OverviewIn this lesson, you learn about important elements and functions of a process orderas well as the typical way it is processed.


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


Business ExampleImportant steps in process order management are order creation, batchdetermination, scheduling, availability checks, release, transfer of control recipesto process control, material withdrawal, confirmations, material delivery, andsettlement. To link the process control level with process control systems andPI sheets, you must set up the process management functions. To manufacturepharmaceutical products, you must implement the following functions: Orderapproval, material identification and reconciliation, in-process quality checks,batch records, digital signature.


TSCM42 Lesson: Elements, Functions, and Processing of a Process Order

Process Order

Figure 19: Processing a Process Order

The procedure involved in process order management can be divided into thefollowing steps:

Process Planning Process Order Execution/Process Management Order Closure

Many of these activities can run automatically or in the background, so thatmanual order management is minimized.

WIP determination, variance calculation, and settlement are generally periodicwork for Cost Object Controlling and are usually processed in the background.

A number of settings available in Customizing allow you to successfully performeach step in order processing.



Figure 20: Elements of the Process Order

Operations describe the different steps required during the production process.For a more detailed description of these steps, operations are assigned phases.

Exactly one resource is assigned to an operation. At the same time, the resourceassignment applies for all phases assigned to the operation.

The processing sequence of the phases is defined in relationships.

The material list is made up of components representing the materials enteringand leaving the production process as well as temporarily existing materialsand their planned quantities. It also defines the assignment of these materialcomponents to phases of the order according to their appearance in the process.

In material quantity calculation, you define formulas to calculate the materialquantities to be used or obtained in a production process, taking into accountthe mixing ratios of the ingredients, yield ratios of the products and remainingmaterials as well as specific material attributes (for example, active ingredients).

Phases are used for scheduling, determining capacity requirements, and costing.The dates and capacity requirements for operations are derived from thecorresponding phases.

Operations and phases can be assigned further resources or secondaryresources, if required. The same business transactions can be executed forsecondary resources as for phases. Secondary resources can, for example, beincluded in scheduling, capacity requirements planning, and costing.



A control key must be entered for both the phases and the secondary resources.The control key is used to determine how an operation or phase is to be treated inoperative applications such as process orders, costing, or capacity requirementsplanning.

A standard value is a planned value used to execute a phase or a secondaryresource such as the execution time. Standard values are used for calculations incosting, scheduling, and capacity requirements planning.

Confirmations are entered for phases and secondary resources (however, not foroperations).

Data for Process Management: Option 1:

Process instructions are structures used to transfer data from process orders toprocess control (PI sheets or process control systems). Process instructions areassigned to the phases of a process order. The process instructions are combinedinto control recipes, which are then transferred to the control recipe destinationsdefined for the phases.

Data for Process Management: Option 2:

The data for process management can be maintained alternatively in the formof XSteps (execution steps) as of SAP R/3 ERP and SCM Extension 2.00(EA_APPL_2.00). Using XSteps allows you to maintain process instructionsin the form of reusable modules that can be referenced. A standard XSteprepository is available with version management.



Order Creation Options

Figure 21: Order Creation Options

To create a process order and a planned order, a suitable production version isdetermined for the material based on the validity period and charge quantity range.

A production version determines which alternative BOM in combination withwhich master recipe is used for production.

If a process order is created without a planned order, it takes the recipe and BOMfrom the production version.

When a planned order is converted, the production version created for it is madeknown to the process order and its recipe is transferred. The BOM is not reread,but rather the dependent requirements of the planned order are converted toreservations for the process order.



Integration with Planning (ECC or SCM (APO))

Figure 22: Integration with Planning (ECC or SCM (APO))

For explanations about planning integration see the unit Order-ControlledProduction with Production Orders. Process orders and production orders behavesimilarly in this regard.



Order Creation with Planned Orders

Figure 23: Order Creation with Planned Orders

For explanations about order creation with planned orders see the unitOrder-Controlled Production with Production Orders. Process orders andproduction orders behave similarly in this regard.



Order Release Functions

Figure 24: Order Release Functions

Process orders have a status management that controls the possible processingsequence of the individual business operations. When an order is released, a statusis set accordingly.

The process order must have the status Released so that the business transactionsfor process order execution and process management can be executed.

You can release individual phases and operations, one complete order, or severalorders at once.

Various activities can be triggered automatically when an order is released:

Batch number assignment for the product Batch determination for the material components Material availability check Control recipe generation Generation of an inspection lot for an in-process quality check

The aims and methods of resource scheduling for process orders are the same asthose for work center scheduling for production orders. They can be found in theunit Order-Controlled Production with Production Orders on the pages Detailedscheduling (work center scheduling) and example: Capacity planning table (APO).



The availability checks for process orders are more or less the same as those forproduction orders. They are described in the unit Order-Controlled Productionwith Production Orders on the page Availability Check for Material, Capacity,PRT. Note here that production resources/tools are not supported in the processorder.

The functions for assigning batch numbers (for the product) and for batchdetermination (for material components) can be used for both process ordersand production orders.

A greater requirement for integration with batch management is usually found inprocess manufacturing.

Batch Determination

Figure 25: Batch Determination

You can use the batch determination function to assign batches with certainmaterial specifications required for production. The system looks for batches instock and selects them according to specific selection criteria.

Based on the selection criteria and a search strategy, the system looks for andselects suitable batches in stock. An availability check is performed at batch level.



The batch determination function is also available for the following applications:

Production order Repetitive manufacturing Sales (sales order and delivery) Inventory management (goods movements) Warehouse management

Process Management

Figure 26: Process Management



Process management is the interface between PP-PI and the systems involved inprocess control. Due to its flexible structure, it can be linked to fully automated,partially automated, and manually operated lines. Process managementincludes the following functions:

Communication with the process control level via the PI-PCS interfaceor PI sheets:

Receiving control recipes with process instructions from releasedprocess orders. The process instructions define in detail the processsteps to be executed and the process data to be confirmed (usingprocess messages).

Manual processing: Displaying control recipes in natural language inthe form of PI sheets so that they can be displayed and maintained onthe screen by the process operator

Automatic processing: Sending control recipes to process controlsystems. The data is transferred via the PI-PCS interface.

Receiving, checking, and sending process messages with actualprocess data from the process control system or the PI sheet. The datais transferred from the external system via the PI-PCS interface.

Reading and writing data points and events using the function SAP OPCdata access (SAP ODA) with the OPC server of the ECC system:

Reading and writing using a PI sheet Reading using the function for automatically creating process messages

Hint: The functions described are available as of Release ECC 6.0Enhancement Pack 3 for production orders also. For productionorders, the synonyms of process integration (= process management),control instructions (= control recipe) and operational method sheet(= PI sheet) are used.



HTML-Based PI Sheet

Figure 27: HTML-Based PI Sheet (I)

Figure 28: HTML-Based PI Sheet II

The SAP PI sheet favors processing on the screen, which means the processoperator is to enter, confirm, or complete data interactively.



In connection with the process instructions contained in a control recipe, the PIsheet has the following elements and functions:

Display of information about the process (control instructions, notes, and soon)

Input fields and tables for entering process data, input validation, signatures Batch determination and batch check Process data calculation Reading and writing data from internal or external applications Link to QM results recording Sequence definition for determining the processing sequence of phases Comments on documentation and messages from process events

PI sheets are created in the HTML layout. The browser-based PI sheet gives youthe advantage of a flexible, user-specific layout definition and allows you to defineframes, for example, for linking to documents, graphics, the Internet, and Intranet.

Material Staging Procedures

Figure 29: Material Staging Procedures

The basis for material withdrawal for process orders are material withdrawalslips, pull lists, pick lists, and similar documents, as well as PI sheets and weighingsystems linked via the PI-PCS interface.



For explanations about material staging see the unit Order-Controlled Productionwith Production Orders. Process orders and production orders behave similarlyin this regard.

Standard Postings for Process Orders

Figure 30: Standard Postings for Process Orders

The standard postings for process orders (goods issue, confirmation, goodsreceipt) can be entered manually in the ECC system, or using process messagesfrom a PI sheet or a process control system.

The functions and procedures for manual entry of process orders are more orless the same as those for production orders. They are explained in the unitOrder-Controlled Production with Production Orders (goods issue posting;order confirmation; confirmation procedures; goods receipt posting).

The process instructions of the order define which process messages are requiredby a PI sheet or a process control system.



Confirmations are entered for phases and secondary resources (and not foroperations). The simplest confirmation procedure is the confirmation for theprocess order.

Hint: Backflushing using process messages from operational methodsheets (= PI sheets) and process control systems is also available as ofRelease ECC 6.0 Enhancement Pack 3 for production orders.

You can also execute backflushing in the SAP MII system.

Flexible Data Entry with Process Messages

Figure 31: Flexible Data Entry with Process Messages

Process messages are data structures with which actual data for a process isconfirmed from process control to one or more destinations.

You can define your own process messages in Customizing according to yourown specific requirements.

The SAP standard system contains a number of predefined message categoriesthat enable you to transfer current data from process control to the ECC system.



Production in Compliance with GMP

Figure 32: Functions for GMP-Compliant Production

The functions for GMP-compliant production (GMP = Good ManufacturingPractice) fulfill special requirements from the pharaceuticals industry (safeproduction, product liability, obligation to produce supporting documents).

The functions flagged with (*) are supported exclusively as part of process orders.The other functions, which are not flagged, can also be used as part of productionorders.

Figure 33: Production in Compliance with GMP



The guidelines on Good Manufacturing Practices (GMP) laid down by the U.S.Food and Drug Administration (FDA) and other international institutions havebecome an international standard in many areas of process industries. In particular,they must be taken into account in processes of the pharmaceutical industry.

You can specify that a process order can only be created if an approved recipeexists. This means the order data is locked and cannot be changed. The approvalprocedure is performed in SAP ECC Engineering Change Management.

You use the material identification function to check whether the material thatwas picked for the process order is completely available at the production line andwill be used in the correct sequence.

You can exchange information about the product quality and analysis valuesbetween the production plant and the laboratory or the quality assurance system.To do this, you use the ECC Quality Management system. The inspectionresults can be automatically transferred to the class characteristics of the batchproduced.

You use thematerial reconciliation function to analyze and verify the ingredientsand yield at the end of the production process.

With regard to product liability, the batch record contains all planned and actualdata for the production process of a batch.

You can activate the digital signature function to execute certain businessoperations in the ECC system.



Enhanced Functions for the Process Order

Figure 34: Enhanced Functions for the Process Order

The functions flagged with (*) are available for process orders only. The otherfunctions listed are also supported in the production order.



Process Manufacturing: Information Systems

Figure 35: Process Manufacturing: Information Systems



55 Exercise 2: Integration with Planning;Process Order Creation with PlannedOrdersExercise Duration: 30 Minutes

Exercise ObjectivesAfter completing this exercise, you will be able to: Execute an MRP planning run for your product Interpret the result of the planning run in the stock/requirements list Convert a planned order into a process order Interpret the result of the planned order conversion in the stock/requirements

list Display a process order, navigate in the order, and name the structure and

basic data

Business ExampleTo find out how order-controlled production with process orders is integratedin supply chain planning, you execute an MRP run in the ECC system for yourproduct T-FI1## Vanilla ice cream - packaged, starting with the existing plannedindependent requirements.

You interpret the planning result in the stock/requirements list:

Planned orders relating to the planned independent requirements are created bythe planning run.

You will then convert a planned order into a process order and interpret the resultsin the stock/requirements list.

Finally, you will display the newly created process order and become familiar withthe structure, navigation, and basic data in the order.

Task 1:

1. Display the current stock/requirements list for your material T-FI1## inplant 1100.

Describe the current situation:




Date MRPElement

MRP ElementData

Rec./ Reqd.qty

AvailableQty

2. Perform multilevel single-item planning for your material T-FI1## in plant1100.

3. After the planning run, display the current stock/requirements list.

Describe the new situation after the planning run:

Date MRPele-ment

MRP elementdata

Rec./Reqd.qty

AvailableQty

Produc-tion ver-sion

Task 2:Display the planned orders from the stock/requirements list.

1. In the Header view, write down the planned creation dates.

Creation date for first planned order: ___________________________

Creation date for second planned order: ___________________________

Creation date for third planned order: ___________________________

Write down the production version selected: _______________




2. Write down the responsible MRP controller given on the Assignment tabpage.MRP Controller: ________________

3. Display the material components from the BOM explosion for the plannedorder.

Task 3:

1. In collective conversion, convert those planned orders within the area ofresponsibility of your MRP controller I## that have a planned opening datein the current week.

Enter the following for planned order selection:

Planning Plant: 1100MRP Controller: I##

Creation: Time period of current week

Choose process order type PI01 for conversion.

2. After planned order conversion, display the current stock/requirements listfor material T-FI1##.

Describe the new situation after planned order conversion:

Date MRPele-ment

MRPelementdata

Rec./Reqd.qty

AvailableQty





Task 4:In change mode, call the new process order from the stock/requirements list.

1. Get an overview of the process order structure and the data in the Header,Operations, and Materials views.

2. Get an overview of the views in the order header.

Write down the order number: __________________________

Pay attention to status management.

3. Get an overview of the data in the following views, in particular:

Header - General Data

Pay attention to the quantity and date fields

Header - Assignment

Write down the production scheduler: ________________________

Header - Goods Receipt

Note the option to define a batch number for product T-FI1##.

Header - Master Data

Write down the production version: ________________________

You can navigate in this view to the master recipe and to the BOM.

4. Display the operation overview of the order.

Compare the entries with the corresponding data in the master recipe.

Get an overview of the detail views of a phase.

5. Display the material list for your order.


Note that the Batch field is ready for input for components that are to bemanaged in batches.

Get an overview of the detailed data of a material component.



Solution 2: Integration with Planning;Process Order Creation with PlannedOrdersTask 1:

1. Display the current stock/requirements list for your material T-FI1## inplant 1100.

Describe the current situation:

Date MRPElement

MRP ElementData

Rec./ Reqd.qty

AvailableQty

a) Logistic Production process MRP evaluations Stock /Requirements List

Material: T-FI1##Plant: 1100

Enter

Date MRPelement

MRP elementdata

Rec./Reqd.qty

Availableqty

Today Stock 0Req. Date IndReq LSF 5000 - 5000 -Req. Date IndReq LSF 5000 - 10000 -Req. Date IndReq LSF 5000 - 15000 -

The quantity available today in the plant stock is 0 kg.

There are 3 future planned independent requirements that are not yetcovered by material requirements planning.




2. Perform multilevel single-item planning for your material T-FI1## in plant1100.

a) Logistic Production process MRP Planning Single item,multi-level


Choose Enter. The system displays a warning prompting you to checkthe input parameters. To start the planning run, choose Enter again.

3. After the planning run, display the current stock/requirements list.

Describe the new situation after the planning run:

Date MRPele-ment

MRP elementdata

Rec./Reqd.qty

AvailableQty





Date MRPele-ment

MRP elementdata

Rec./Reqd.qty

AvailableQty


a) Logistic Production process MRP evaluations Stock /Requirements List


Enter

Date MRPelement

MRPelementdata

Rec./Reqd.qty

Availableqty

Pro-ductionversion

Today Stock 0Plannedreceipt

PLOrd Num-ber/Stck

5000 5000 0001

Req. Date IndReq LSF 5000 - 0Plannedreceipt

PLOrd Num-ber/Stck

5000 5000 0001


PLOrd Num-ber/Stck

5000 5000 0001

Req. Date IndReq LSF 5000 - 0

As a result of the planning run, the system created planned orders tocover the planned independent requirements.

Task 2:Display the planned orders from the stock/requirements list.

1. In the Header view, write down the planned creation dates.

Creation date for first planned order: ___________________________

Creation date for second planned order: ___________________________




Creation date for third planned order: ___________________________

Write down the production version selected: _______________

a) To display a planned order:

Double-click the MRP element PLOrd., choose the Display Element(F7) icon

Header tab page:

Opening: Planned opening date

The opening date is used as a selection criterion for the collectiveconversion of planned orders into process orders.

Production Version: 0001

2. Write down the responsible MRP controller given on the Assignment tabpage.

MRP Controller: ________________

Answer: Assignment tab page:MRP Controller: I##

3. Display the material components from the BOM explosion for the plannedorder.

a) To display the components:

Choose Components (F5)

Task 3:

1. In collective conversion, convert those planned orders within the area ofresponsibility of your MRP controller I## that have a planned opening datein the current week.

Enter the following for planned order selection:






Choose process order type PI01 for conversion.

a) Logistic Production process Process order Process orderCreate With Planned Orders



Process Order Type: PI01

Choose the Execute Selections (F8) icon. The Collective Conversion ofPlanned Orders: List screen appears.

According to the selection criteria, the system only displays the plannedorder for material T-FI1## that is chronologically first.

Select the corresponding line in the list and choose Convert.

After the conversion, the system displays the number of the createdprocess order in the lower message bar.

To exit collective conversion, choose Back (F3).

2. After planned order conversion, display the current stock/requirements listfor material T-FI1##.

Describe the new situation after planned order conversion:

Date MRPele-ment

MRPelementdata

Rec./Reqd.qty

AvailableQty





Date MRPele-ment

MRPelementdata

Rec./Reqd.qty

AvailableQty


a) Logistic Production process Process Order Environment Stock/reqmts list


Enter

Date MRPele-ment

MRPelementdata

Rec./Reqd.qty

Availableqty

Pro-ductionversion

Today Stock 0Plannedreceipt

PR-ORD Num-ber/Stck

5000 5000 0001


PLOrd Num-ber/Stck

5000 5000 0001


PLOrd Num-ber/Stck

5000 5000 0001

Req. Date IndReq LSF 5000 - 0

The planned order has been converted into a process order.




Task 4:In change mode, call the new process order from the stock/requirements list.

1. Get an overview of the process order structure and the data in the Header,Operations, and Materials views.

a) To call the process order in change mode:

Double-click MRP element PR-ORD

Choose the Change Element (F8) icon

Choose the appropriate buttons to navigate.

2. Get an overview of the views in the order header.

Write down the order number: __________________________

Pay attention to status management.

a) The order number varies.

3. Get an overview of the data in the following views, in particular:

Header - General Data

Pay attention to the quantity and date fields

Header - Assignment

Write down the production scheduler: ________________________


Note the option to define a batch number for product T-FI1##.


Write down the production version: ________________________

You can navigate in this view to the master recipe and to the BOM.

a) Header - Assignment

Production Scheduler: I##


The Batch field is ready for input.


Production Version: 0001

4. Display the operation overview of the order.





Get an overview of the detail views of a phase.

a) Choose Operations.

Double-click the phase number to display the detail view of a phase.

5. Display the material list for your order.


Note that the Batch field is ready for input for components that are to bemanaged in batches.

Get an overview of the detailed data of a material component.

a) Choose Materials.

The Batch field is ready for input for components that are to bemanaged in batches.

Double-click the item number to display the detailed data of a materialcomponent.



67 Exercise 3: Process Order Release;Processing an Order with a PI SheetExercise Duration: 30 Minutes

Exercise ObjectivesAfter completing this exercise, you will be able to: Release a process order Generate a control recipe for a process order Edit a PI sheet Send process messages Check the results of order processing

Business ExampleYou release your order for material T-FI1## and generate the control recipe for theorder at the same time.

You select and send your control recipe in the control recipe monitor.

You edit the PI sheet.

You select and send the process messages created while you were editing the PIsheet in the message monitor.

After sending the messages, you check the current data in the process order, thestock/requirements list, and in inventory management.

Task 1:

1. Release your process order for the production of material T-FI1## incollective processing. At the same time generate the control recipe for theorder.

Enter the following criteria for order selection:

Order Type: PI01Plant: 1100Production Scheduler: I##




Do not enter any selection criteria for the release date (or set the selectionperiod so that your orders scheduled release date corresponds to theselection criteria).

2. Display your process order now that it has been released and the controlrecipe has been generated.

Find out which activities were performed when the order was released.

Look at the order status. Note, in particular, the statuses REL, CRCR, BCRQ,BASC, and MACM.


Note that a batch number was created automatically for the product T-FI1##.

Material List

Note that batch determination was executed automatically for materialcomponents subject to batch management requirement.

3. Select your control recipe in the control recipe monitor.

Send the control recipe and update the list display.

Hint: In the manufacturing plant, control recipes are sentautomatically in a job.

4. Your control recipe destination is of the type PI sheet.

Select and edit the PI sheet created when the control recipe was sent.

Edit the PI sheet as specified in the solutions for this exercise.

5. Select the process messages created by maintaining the PI sheet in themessage monitor.

Send the process messages.

Hint: In the manufacturing plant, process messages are sentautomatically in a job.

Task 2:Display the process order for material T-FI1##.

1. On the Header Data screen, check the data for the quantity produced andthe confirmed dates.

Note the order statuses DLV and CNF.




2. Go to the Operation Overview and display the confirmed dates and calculatedactivities for some of the phases.

3. Go to the Material List and display the quantities that have been issuedfor some of the materials.

Task 3:

1. Display the current stock/requirements list for material T-FI1##.

Describe the new situation:

Date MRPelement

MRPelementdata

Re-ceipt/re-quire-ment

Availablequantity

Productionversion

2. Display the stock overview for material T-FI1##.



Solution 3: Process Order Release;Processing an Order with a PI SheetTask 1:

1. Release your process order for the production of material T-FI1## incollective processing. At the same time generate the control recipe for theorder.

Enter the following criteria for order selection:


Do not enter any selection criteria for the release date (or set the selectionperiod so that your orders scheduled release date corresponds to theselection criteria).

a) Logistics Production - Process Process Order Process Order Release


Delete the entries in the fields for date selection.

Choose the Execute Selections (F8) icon.

The Release Process Order: List screen appears.

In accordance with the se

tscm42_en_col92_fv_inst_a4.pdf

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