afs combined orders

EHP3 for SAP ERP 6.0

March 2009

English

Combined Production Orders (635)

SAP AGDietmar-Hopp-Allee 1669190 WalldorfGermany

Business Process Documentation

SAP Best Practices Combined Production Orders (635): BPD

Copyright

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Business Process Alternative/Decision Choice

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Cross-references to other documentation.

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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 Preliminary Steps............................................................................................................7

2.4 Roles............................................................................................................................... 7

3 Process Overview Table.........................................................................................................8

4 Process Steps........................................................................................................................9

4.1 Prerequisite.....................................................................................................................9

4.2 Maintaining Distribution of Requirements......................................................................10

4.3 Creating Planned Independent Requirements...............................................................11

4.4 Creating Planned Order in MRP....................................................................................12

4.5 Converting a Planned Order to a Production Order.......................................................13

4.6 Combining Production Order.........................................................................................14

4.7 Releasing Combined Order...........................................................................................15

4.8 Confirmation of Combined Order/ Component Consumption........................................16

4.9 Confirmation of Production Order Operations (Time Ticket)..........................................16

4.10 Entering Goods Receipt for Manufactured Goods.....................................................17

4.11 Comparing Planned and Actual Costs.......................................................................18

5 Follow-up Processes............................................................................................................19

6 Appendix.............................................................................................................................. 20

6.1 Reversal of Process Steps............................................................................................20

6.2 SAP ERP Reports.........................................................................................................20

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Combined Production Orders

1 Purpose This scenario describes the production processes that involve combined Production Orders for Apparel and Footwear Industry. This function allows grouping several production orders that use the same component or have the same operation in the routing.

The scenario uses the AFS functionality, which is a comprehensive solution based on the ERP Standard, and is designed to meet the specific needs of the Apparel and Footwear industry. The AFS-specific features allow materials to be managed at the Stock keeping unit level (SKU). The materials are classified according to certain characteristic values, for example size, color and quality, which brings data to the lower level and influences the entire logistical process.

The basic data in the area of production planning and control, that is, bills of material and routings, have also been modified to accommodate the requirements of the Apparel and Footwear industry. Bills of material and routings contain characteristic values of the corresponding materials.

The process involves using raw materials AFS-R2306 (Jersey Fabric), AFS-R2308 (Label), AFS-R2316 (Yarn) and AFS-R2317 (Box) to assemble the finished products AFS-F1306 and AFS-F1307 (T-Shirt Print A and B) in plant 1000.

You begin the process by manually creating planned independent requirements. You maintain AFS planned independent requirements by category, version, and requirements plan number. When working with planned independent requirements, you must also select whether you want to work at material level or SKU level.

AFS-MRP single-item is run to plan components for the internally manufactured material. When MRP has run, the system brings the user to the Stock Requirements List for the desired material. MRP will create ‘Planned Orders’, which will be converted into Production Order from AFS Stock Requirements List order in the next step. You then will combine the production orders of the two different Materials. While confirming the production order, the goods issue for the BOM components is posted automatically. You then post the goods receipt for the finished products. You complete the production process with order confirmation by calculating the actual costs.

Finally you calculate the overhead cost and order settlement.

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2 Prerequisites

2.1 Master Data and Organizational DataDefault ValuesEssential 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 FocusSAP 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 ValuesYou 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 DataYou 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:

Master / org. data Value Master / org. data details Comments

Company Code 1000 Company Code 1000

Plant 1000 Production Plant

Storage Location 1040 Finished Goods

Storage Location 10F1 AFS: Raw material

Material: AFS-F1306 T-Shirt Print A (FERT)

Material: AFS-F1307 T-Shirt Print B (FERT))

Material: AFS-R2306 Jersey Fabric (ROH)

Material: AFS-R2308 Label (ROH)

Material: AFS-R2316 Yarn (ROH)

Material: AFS-R2319 Box (ROH)

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Master / org. data Value Master / org. data details Comments

Work center: F-CUT Cutting

Work center: F-SEW Sewing

Work center: F-FOLD Fold & Pack

Work center: F-CUT Cutting

2.2 Business ConditionsThe business process described in this Business Process Documentation (BPD) is part of a bigger chain of integrated business processes or scenarios. As a result, you must have completed the following processes and fulfilled the following business conditions before you can start any activities in this scenario:

Business condition Scenario

To run through this scenario, some prerequisite processes steps have to be done.

To Execute this activity, run the Business Process Procedure for Prereq. Process Steps (BB - 154) scenario.

The following steps are required:

Roll MM Period to Current Period

Product Costing: Costing Run

Initial stock postings

Prereq. Process Steps (BB - 154)

2.3 Preliminary Steps

2.4 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.

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

Business role Technical name Process step

Shopfloor Specialist (AFS)

SAP_BPR_SHOPFLOORSPECIA_AFS-K Maintaining Distribution of Requirements

Combining Production Order

Releasing Combined Order

Confirmation of Combined Order/ Component Consumption

Production Planner (AFS)

SAP_BPR_PRODUCTIONPL_AFS-S Creating Planned Independent Requirements

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Business role Technical name Process step

Creating Planned Order in MRP

Production Planner

SAP_BPR_PRODUCTIONPLANNER_EX-S Converting a Planned Order to a Production Order

Shop Floor Specialist

SAP_BPR_SHOPFLOORSPECIALIST-S Confirmation of Production Order Operations (Time Ticket)

Comparing Planned and Actual Costs

Warehouse Clerk

SAP_BPR_WAREHOUSESPECIALIST-S Entering Goods Receipt for Manufactured Goods

ResultYou can now process the scenario Combined Production Orders (635).

3 Process Overview Table

Process step External process reference

Business condition

Business role

Trans-action code

Expected results

Maintaining Distribution for Requirement

Production Planner

J4A1 Distribute profile is created

Creating Planned Independent

distribution profile is created

Production Planner

J3A1 Planned Independent Requirement

Create Planned Order in MRP

There are requirements from customer

Production Planner

/n/AFS/MD02 Create planned order for the material

Converting a Planned Order to a Production Order

– – Production Planner

MD04 Production orders are created

Combine Production Order


/AFS/CORD Production orders with the same components are combined

Release Combine Order


J4A| Order is released

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Process step External process reference

Business condition

Business role

Trans-action code

Expected results

Confirmation of Combine Order/Component consumption

– Shop Floor Specialist

J4A| Operation confirmed

Confirmation of Production Order Operations(Time Ticket)

Shop Floor Specialist

CO11N Operation confirmed

Enter Goods Receipt for Manufactured Goods

Warehouse Clerk

MIGO_GO Goods Receipt for the material

Compare Planed and actual cost

Cost Controller

CO03

Period End Procedure

Period End Procedure(181)

See scenario no. 181

See scenario no. 181

4 Process Steps

4.1 Display components stockYou should check the component stock status using Transaction Code (MMBE), Ensure the following stock is in the storage location 10F1, in plant 1000.This should be done in the Final Step after installation.

Material ShortText

Quantity (Qty in UnE)

Storage Location(Stor.Loc)

Grid value StockCategory

Comment

AFS-R2308 30000 10F1 Line 1

AFS-R2316 30000 10F1 BLK Line 2

AFS-R2319 30000 10F1 Line 3

AFS-R2306 30000 10F1 BLK Line 4

If the stock is not enough in the storage location 10F1, use MIGO_GO to do the Goods receipt for the above materials.

4.2 Maintaining Distribution of Requirements

Use

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You are going to plan your demands on Material/ Category level and to break down this total demand to the single sizes. To be able to do so, you need Distribution Profiles to break down with aggregation factors.

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

Option 1: SAP Graphical User Interface (SAP GUI)

SAP ECC menu Logistics Production Production Planning AFS Profiles Distribution Profiles Maintain

Transaction code J4A1

Option 2: SAP NetWeaver Business Client (SAP NWBC) via business role

Business role Shopfloor Specialist (AFS) (SAP_BPR_SHOPFLOORSPECIA_AFS-K)

Business role menu Production Planning AFS Profiles J4A1 - AFS Maintain distribution of reqmts

2. On the AFS Maintain Distribution Profiles screen, make the following entries:

Field name Description User action and values Comment

Material-Based AFS-F1306

Distribute requirements to Mark: Grid values

3. Choose Enter.

4. Enter following data on the pop-up Parameters screen:


Plant 1000

Category * For all

Val.period * For all

Distr.ver 00

5. Choose Enter.

6. Choose the menu (More ) Edit Grid processing (Shift+F8).

7. On the Maintain Distribution of Requirements to grid values screen, enter the Disaggregation Factor for each size and color BLK: for example,

XS S M L XL XXL XXXL

10 20 30 40 40 30 20

The system then calculates the percentage automatically.

8. Choose Back (F3).

9. Choose Save.

10. Repeat step 1 to 9 for Material AFS-F1307

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11. Choose Back (F3) to go back to the SAP Easy Access screen (SAP GUI) or choose Exit (Shift+F3) and confirm the Business client message with Yes to return to SAP Home (SAP NetWeaver Business Client).

Result You created Distribution Profiles for Plant 1000 for Material AFS-F1306 and AFS-F1307. Planned independent Requirements will be disaggregated using this Profile.

4.3 Creating Planned Independent Requirements

UseYou create the planned independent requirements and determine the requirement dates and requirement quantities of the material.



SAP ECC menuLogistics Production Production Planning Demand Management AFS Planned Independent Requirement Maintain

Transaction code J3A1


Business role Production Planner (AFS)

(SAP_BPR_PRODUCTIONPL_AFS-S)

Business role menu Production Planning Demand Management AFS Maintain planned requirements

2. On the AFS Planned Independent Requirement screen, make the following entries:


Material AFS-F1306

Plant 1000

Category 1IN

ReqPlanNo

Version 00

Materials level Mark

SKU level

3. Choose Enter.

4. In the following schedule line table, make the following entries::


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Period Period indicator M (Month) Line 1

Reqmt.date Requirement date Today + 1 month (for example, 01.2009) Line 1

Planned Quantity

500 Line 1

Make sure the Flag ACTIVE is set!

5. Choose Presizing (Shift +F8).

6. On the following Presizing screen, make sure that Target period is M (Month).

7. Choose Enter.

8. You may now check how the system disaggregated the total demand to the single sizes and make changes.

9. Choose Save.

10. Repeat step 2 to 10 for material AFS-F1307.


Result You have created the planned independent requirements for the material / Category.

4.4 Creating Planned Order in MRP

UseThe purpose of this activity is to use material requirements planning (MRP) to generate planned orders for the materials that are to be produced.



SAP ECC menu Logistics Production MRP AFS Planning Single-Item Planning

Transaction code /N/AFS/MD02


Business role Production Planner (AFS)

(SAP_BPR_PRODUCTIONPL_AFS-S)

Business role menu Production Planning MRP AFS-MRP: Single-item Planning

2. On the AFS MRP Single-Item, single-level/Multi-Level screen, enter the following data:

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Material AFS-F1306

Plant 1000

AFS MRP Control Parameters

Create Pur Req 1

Planning Mode 3

Scheduling 1

Process Control Parameters

Also plan All Components

X (Mark)

Display MRP Result

X (Mark)

3. Choose Enter twice.

4. Choose Back (F3).

5. Repeat step 1 to 5 for material AFS-F1307


ResultYou have created planned orders for the material AFS-F1306 and AFS-F1307. You can display the planned orders that are generated in the current stock/requirements list (transaction /N/AFS/MD04).



SAP ECC menu Logistics AFS Central Functions AFS Material Requirements Planning AFS Evaluation AFS Stock/Reqs list

Transaction code /n/AFS/MD04


Business role Production Planner (AFS) (SAP_BPR_PRODUCTIONPL_AFS-S)

Business role menu Production Planning MRP AFS Stock/Requirements List

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

Field name User action and values Comment

Material AFS-F1306

or AFS-F1307

Plant 1000

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3. Choose Enter.

4. You will see list of stock according to AFS MRP status.


4.5 Converting a Planned Order to a Production Order

UseWhen a planned order is converted to a production order, the product, the order quantity, and the basic order date are adopted from the planned order. The BOM components are also reserved for production.



SAP ECC menu Logistics Production MRP Evaluations Stock/Requirement List

Transaction code MD04


Business role Production Planner

(SAP_BPR_PRODUCTIONPLANNER_EX-S)

Business role menu Production Planning MRP Stock/Requirements List - Individual Display

2. On the AFS Stock/Reqs.List initial screen, make the following entries:


Material AFS-F1306

Plant 1000

3. Choose Enter.

4. Double-click one line of the planned order number (Type PldOrd).

5. On the pop-up Additional data for MRP Element screen, choose Prod.ord.

6. Verify that Production Order info is correct and save (Ctl+S) production order.

7. Note the production order number.

8. Choose Exit (Shift+F3).

9. Repeat step 1 to 8 for material AFS-F1307


Result

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The planned order has been deleted and a production order has been generated.

4.6 Combining Production Order

UseThe purpose of this activity is to combine the production orders you created in the last step to produce them at once.



SAP ECC menu Logistics Production Shop Floor Control Order AFS Combined Orders Group AFS Production Orders

Transaction code /n/AFS/CORD



Business role menu Shop Floor AFS Group Production Orders

2. On the Group production orders via combined order number screen, choose Operations and components tab page and make the following entries:


Plant 1000

Component AFS-R2306

Include backflushed components

3. Choose Execute (F8).

4. All production orders with the component AFS-R2306 (fabric) are shown. Select Orders in previous step and choose Combine Int. Numb. (Shift + F1).

5. Note the combined order number that is displayed in the Combined Order column

6. Choose Save (F11).

7. Choose Back (F3) to go back to the SAP Easy Access screen (SAP GUI) or choose Exit (Shift+F3) and confirm the Business client message with Yes to return to SAP Home (SAP NetWeaver Business Client)..

ResultThe production orders are grouped to a combined order.

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4.7 Releasing Combined Order

UseThe purpose of this activity is to release the combined order you created in the last step.



SAP ECC menu Logistics Production Shop Floor Control Order AFS Combined Order Additional Function

Transaction code J4A|



Business role menu Shop Floor AFS Combined orders further functions

2. Enter combined order number you have created in the step 4.6 Combining Production Order.


4. On the Combined Orders – Release/Confirm/Goods Issue screen, choose Select all (F7) and then Release (Shift+F6).

5. Choose Continue (Enter) on the following pop-up Released Messages screen.


4.8 Confirmation of Combined Order/ Component Consumption

UseTo collect activity costs you create an order confirmation. Each material component is assigned to an operation in the production order. Since the material components are backflushed, the system posts the withdrawal only upon confirmation of the operation. The withdrawal is then posted automatically. You see the Backflush flag in the component view of the production order (Transaction CO03).

This process step will confirm the first operation for all production orders of the combined order.



SAP ECC menu Logistics Production Shop Floor Control Order AFS Combined Order Additional Function

Transaction code J4A|

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Business role menu Shop Floor AFS Combined orders further functions

2. Enter combined order number you have created in 4.6 Combining Production Order


4. On the Combined Orders – Release/Confirm/Goods Issue screen, choose Select all (F7) and then choose Confirm operation (F6).

5. On the Choose operation to confirm screen, double-click the operation 0010 of the first production order.

6. Choose Continue (Enter) on the Confirm messages screen that shows the results of the confirmations.

7. Choose Continue (Enter) on the Choose operation to confirm screen


ResultThe first operation is confirmed, actual costs are calculated and goods movements are posted.

4.9 Confirmation of Production Order Operations (Time Ticket)

UseA confirmation documents the processing status of orders, operations, sub operations, and individual capacities. This process step will confirm the other operations of each production order manually. The first operation was confirmed based on the combined order previously.



SAP ECC menu Logistics Production Shop Floor Control Confirmation Enter For Operation Time Ticket

Transaction code CO11N


Business role Shop Floor Specialist

(SAP_BPR_SHOPFLOORSPECIALIST-S)

Business role menu Shop FloorDiscrete Enter Time Ticket for Production Order

2. Enter the production order you have created in step 4.5 Converting a Planned Order to a Production Order and the operation. Repeat Step 3 to 5 for each line of following data:

Production order Operation

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Your first order # 0020

Your first order # 0030

Your second order # 0020

Your second order # 0030

3. Choose Enter.

4. Optional: Choose Goods movements (Shift+F6).

5. Choose Save.


ResultActual costs are calculated. Goods movements are posted.

4.10 Entering Goods Receipt for Manufactured Goods



SAP ECC menu Logistics Materials Management Inventory Management Goods Movement Goods Receipt GR for Order

Transaction code MIGO_GO


Business role Warehouse Clerk

(SAP_BPR_WAREHOUSESPECIALIST-S)

Business role menu Warehouse ManagementReceivingOther Goods Movement

2. On the Screen, make the following entries:


Action Goods Receipt

Reference Order

Movement type 101

Order number Production Order 1

3. Choose Enter.

4. Mark the OK flag for all lines and choose Save (F11).

5. Repeat step 2 to 4 for the second production order.


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ResultThe goods receipts are posted for the production order. A goods receipt document has been created and the postings to FI and CO have been made.

Posting Key Account Description Amount Cost element / CO object

89 22201100 Stock of finished goods 62,480.25

91 41201100 Change in stock of finished goods

62,480.25-

4.11 Comparing Planned and Actual Costs



SAP ECC menu Logistics Production Shop Floor Control Order Display

Transaction code CO03

2. On the Production Order. Display screen, in the Order field, enter the order number that you have created in step 4.6 Combining Production Order and choose Enter.

3. From the menu bar, choose Goto Costs Analysis.

4. Choose Select Layout (Ctrl+F9) and choose Layout 1SAP02 (Cost Trent) if no layout is predefined.

5. The costs of the confirmations, goods issue and goods receipt are shown.

6. Choose Back (F3) to go back to the SAP Easy Access screen (SAP GUI)


Business role Shop Floor Specialist

(SAP_BPR_SHOPFLOORSPECIALIST-S)

Business role menu Shop FloorDiscrete

1. Select the row of your Production Order from the Powerlist (Main Tab All Production Orders).

2. Choose Process Production Order and choose Display Order from the pull down list.

3. On the Production Order. Display screen, in the Order field, enter the order number and choose Enter.

4. Choose More. From the menu bar, choose Goto Costs Analysis.

5. Choose Select Layout (Ctrl+F9) and choose Layout 1SAP02 (Cost Trent) if no layout is predefined.

6. The costs of the confirmations, goods issue and goods receipt are shown.

7. Choose Back (F3) to go back to the SAP Easy Access screen (SAP GUI) or choose Exit (Shift+F3) and confirm the Business client message with Yes to return to SAP Home (SAP NetWeaver Business Client)..

Result

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Order confirmation completes the production process of this material. The actual costs are calculated and goods receipt is posted to unrestricted-use stock.

5 Follow-up Processes

You have finished all activities that are a part of the business process described in this document.

To accomplish subsequent activities of this business process, carry out the process steps described in the referenced scenario, using the master data from this document.

Period End Closing “General” Plant (181)

UseIn this activity, the production/process orders that are no longer active need to be flagged as closed so that future postings will not be allowed.

ProcedureBPD covers the period end closing for product cost controlling by period and product cost controlling by order. The procedures for Product Cost by Order are the same regardless of whether a manufacturer uses process orders or production orders. When differences occur, a special note makes clarification

6 Appendix

6.1 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 for finished product

Material Staging for Order

Confirmation for production order

Transaction code (SAP GUI) CO11N

Reversal: cancel confirmation

Transaction code (SAP GUI) CO13

Business role Shop Floor Specialist (SAP_BPR_SHOPFLOORSPECIALIST-K)

Business role menu Shop FloorDiscreteCancel Confirmation of Production Order

Comment Cancel confirmation for production order

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Goods receipt from production

Transaction code (SAP GUI) MIGO

Reversal: Cancel process order confirmation

Transaction code (SAP GUI) CORS

Business role Shop Floor Specialist (SAP_BPR_SHOPFLOORSPECIALIST-S)

Business role menu Shop FloorProcessCancel process order confirmation

Comment If backflushing had been used for components issue, the relevant material movement is cancelled as well

6.2 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 Reports 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.

ReportsReport title Transaction

codeComment

Missing Parts Info System CO24 A list of missing parts.

Production Order Information System

COOIS A list of all production orders.

MRP List MD05 The stock/requirements situation at the time of the last planning run.

Stock Overview MMBE A list of stock is displayed.

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afs combined orders

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