material configurable sap

2008 Wellesley Information Services. All rights reserved.

Exploiting Variant Configuration for Use in Advanced Planning and Modeling

Jean-Yves PopovicADELANTE

11

What Well Cover

Introduction: Variant Configuration (VC) concepts review Material Variants (Type Matching) and Variant Pricing

(SD, MM) More on Object Dependencies Configuration scenarios Planning for VC Engineering and Order Change Management (ECM

and OCM) Sales Configuration Engine (SCE) and Internet Pricing

and Configuration (IPC) Miscellaneous: Performance, client management, and

modeling tips Wrap-up

222

Who Should Use Variant Configuration?

Example of industries relevant to SAP VC:

Aircraft

Bicycle

Motorcycles

ElevatorSystems

PCs

Pumps

Furniture

ProductComplexity

MassProduction

Automobiles

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333

VC Concepts and Functionalities

Process flow:

Sales Quote Prod Order

Purch Order

Sales/Customer Services Engineering Production/Procurement

Order BOM

Sales Order

bodybody

seats

car

bodyinterior

seats dashboard

Super BOM

Op.30

Op.20

car

Op.10

Super Routing

+ +

444

Variant Configuration Knowledge Base

Variant Class

Characteristic: Bread Type

RegularItalianHerbs

Desc.: Italian BMTType: 300

6

Characteristic: Length

12

Possible Values:

Possible Values:

Material MasterMaterial Type: KMATDesc.: Italian BMTVariant Class:

ConfigurationProfile

Super BOM

Super Routing

Dependencies

Precondition (PC)Selection Condition (SC)Procedures (P)Constraints (C)

Op. 10 ...Op. 20 ...

Item 10: ... Item 20: ...

PricingConditions

...

Order BOMBOM explosionUser Interface

55

What Well Cover






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66

Material Variants: Concept

Definition: A material variant is a material that is kept in stock and that is

a specific configuration of a configurable material Purpose:

Planning (forecast, Make-To-Stock) Pre-Assembly Sales Order (delivery date: ATP)

Type Matching: When assigning value to a configurable material, the system

will look for a material variant

77

Material Variants: Material Master

Create Material Master (material type must allow for stock): Basic Data 2 view:

OR:

MRP 3 view:

Note: Cross-plant configurable material can only be used in

purchasing Values assigned are stored in the Material Master record

Reference the Configurable

Material

Bring the Configuration screen(Value Assignment)

88

Material Variants: BOM

Create a new BOM or link the material variant to the BOM of the configurable material:

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9 Create a new Routing or link the material variant to the Routing of the configurable material: Using transaction CA02, assign the material variant to the

routing of the configurable material

9

Material Variants: Routing

10

Material Variants: Type Matching Settings

In the configuration profile (use transaction CU42) of the configurable material:

On request or permanent (performance!)

Type Matching performed as configuration is done (partial)

or when it is finished (complete) (performance!)

Warning

Warning

1111

Material Variants: Results

Using Configuration simulation (transaction CU50):

Appears as soon as theconfiguration matches

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1212

Variant Pricing: Concept

The configurable material has a basic price You can define surcharges/discounts (variant

conditions) that depend on characteristic values Condition types VA00 (absolute amounts) and VA01

(percentage amounts) are defined for variant conditions Variant conditions can be created with reference to a

material, a distribution channel, and a sales organization You assign variant conditions to characteristic values

1313

Variant Pricing: Surcharge/Discount Characteristic

1. Create a multiple-value characteristic with reference to field SDCOM-VKOND:

1414

2. Create a condition record of condition type VA00 (absolute) or VA01 (percentage): Key field Variant is your choice; this is the variant condition

key that you will use in dependencies (caution: case-sensitive)

Make sure your pricing procedure reads condition types VA00 and/or VA01

Variant Pricing: Surcharge/Discount Characteristic (cont.)

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1515

3. Using the configuration simulation (transaction CU50), assign the condition record to the characteristic value:

Variant Pricing: Assignment or Dependency

1. F4 on the value field

2. Select the value

3. Click on the Variant Condition icon 4. Save

16

4. In the Sales Order entry screen (base price = 5 EUR):

16

Variant Pricing: Results

1717

Dependencies: Instead of assigning condition records to characteristics

value, you can use dependencies (procedures) to the configuration profile:fExample:

$self.Z_SURCHARGE = surcharge_bread if Z_BREAD eq D

Variant Pricing: Others

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1818

Pricing Factor: You can assign a pricing factor to the variant condition The factor can be a constant, a numeric characteristic, or a

numeric expressionf$self.Z_SURCHARGE = surcharge_breadf$SET_PRICING_FACTOR ($self, Z_SURCHARGE,

surcharge_bread, BREAD_SIZE/12) This will alter the surcharge (based on bread type) by a factor

that is based on the bread size

Variant Pricing: Others (cont.)

1919

Variant Pricing in Purchasing (MM)

Same technique as for sales, using condition records of condition type VA00 or VA01, except: The reference characteristic refers to MMCOM-VKOND Only assign condition records using dependencies

2020

What Well Cover


(SD, MM) More on Object Dependencies Configuration scenarios Planning for VC Engineering and Order Change Management (ECM and

OCM) Sales Configuration Engine (SCE) and Internet Pricing



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2121

Object Dependencies: Dependency Types

Declarative: Point in time and sequence not relevant to the result Constraints and Actions (obsolete)

Semi-declarative: Like declarative, but processed procedurally Preconditions Selection conditions

Procedural: Result depends on processing sequence and point in time Procedures

2222

Object Dependencies: Dependency Types (cont.)

Dependency Usage BOM ItemRouting Op. CharacteristicCharacteristic

ValueConfiguration

Profile

Pre-condition

(PC)

Can a characteristic (or char. value) be selected?

Selection Condition

(SC)

Must a char. (or char. value) be selected?

Procedure(P)

Infer values, including reference data (overwrite, recursive)

Constraint(C)

Infer values and consistency check (multi-level)

Sem

i-dec

lara

tive

Dec

lar-

ativ

ePr

oce-

dura

l

2323

Object Dependencies

Processing sequence in value assignment: ENTER

1. Default values for characteristics2. All procedures, exactly once, in the following

sequence: Configuration profile Characteristics Characteristic values

3. All preconditions and then all selection conditions

Characteristic Value

Constraints

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2424

Object Dependencies: Constraints

Designed for multi-level complex interactive configuration (but useful for single-level configuration)

Infer values and check configuration consistency Between any objects in a configuration task

Active in configuration only No effect on BOM and task-list explosion in low-level

configuration (in MRP, for example) Cannot replace selection conditions and procedures

Constraints are not assigned directly to individual objects. They are grouped together to form a dependency net and assigned to a configuration profile.

2525

Object Dependencies: Constraints Structure

Constraints Structure: OBJECTS:

fSpecify the objects that are relevant to the constraint (class, characteristic, material)

fVariables can be defined CONDITION (optional):

fCondition that must be fulfilled to process the constraint RESTRICTIONS:

fRelation between elements in the Objects section that must be true (consistency check and inference)

fDirect or using variant functions and variant tables INFERENCES (optional):

fApplies to formulas in the restrictionfTable calls or function calls

2626

Object Dependencies: Example of Constraint

BOX is a class, with four characteristics (Length, Width, Height, and Volume)

If any three of the variables are known, the fourth is automatically inferred.

OBJECTS:(300) BOX,where L = Length;

W = Width;H = Height;V = Volume.

RESTRICTIONS: V = L * W * H.INFERENCES: V = L * W * H.

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2727

Object Dependencies: Variant Tables

Variant tables describe allowed combinations of values in Selection Conditions, Preconditions, Procedures, and Constraints

Can infer values in procedures and constraints Restrictions:

Recommended to use single-value characteristics

You cannot define dependencies for table entries

It is possible (recommended) to link existing variant tables to new database tables (performance)

2828

Object Dependencies: Create Variant Tables

29

Object Dependencies: Table Contents

Table display options:

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3030

OBJECTS:PC IS_A (300)PC.

RESTRICTIONS:table CS (PRINTER = PC.PRINTER,

MONITOR = PC.MONITOR,CPU = PC.CPU).

INFERENCES:PC.PRINTER,PC.MONITOR,PC>CPU.

Object Dependencies: Variant Tables (Example)

Characteristic: PRINTER MONITOR CPU

Key? X X X

Allowed Values:

Inkjet 20 Standard

Laser_1 21 Medium

Laser_2 24 Fast

Constraint:

Variant Table CS

Result: If each characteristic is a key (no ambiguity), only one characteristic value needs to be assigned in order to infer the other two

3131

Object Dependencies: Variant Functions

You can call a function module (ABAP program) in a dependency

Procedure: Define input and output characteristics Define an ABAP program (function module) Create a function that calls the ABAP program Enter the function in a dependency (a procedure, for example)

3232

What Well Cover






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3333

Configuration Scenarios

Variant Configuration is not limited to configuring the header material

Typically, subassemblies can be configured as well The corresponding materials will be set accordingly

(configurable material, super BOM, configuration profile, etc.)

car

engine bodyinterior

seats

fabric frame

dashboard

KMAT

KMAT

KMAT

3434

Configuration Scenarios (cont.)

The configuration parameters section of the configuration profile includes Process parameters and BOM explosion parameters

The combination of the two determines the behavior of the entire configuration process

3535

Configuration Scenarios: Plnd/Prod Order Process

The final configuration is determined at Sales Order entry during configuration (value assignment process)

Single or Multi-level configuration in the Sales Order Header material is configured interactively Lower-level configurable items (not only sales-relevant items)

can be configured interactively (if explosion) Pricing at header material level No Order BOM:

Only value assignment in the configuration process determines the BOM components

One (or more) lines in the Sales Order, and one (or more) new BOMs with reference to the line item

Examples: Automobiles, bicycles, catalogue furniture,

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3636

Configuration Scenarios: Sales Order (SET)

Usage: kits (or sets) As in Plnd/Prod Order, the final configuration is

determined at Sales Order entry during configuration (value assignment process)

(No single) multi-level configuration in the Sales Order Header material is configured interactively, as well as lower

level configurable items (but only sales-relevant items) Pricing at header material level or at sub-item level No Order BOM:

Only value assignment in the configuration process determines the BOM components

Several lines in the Sales Order Examples:

PC packages (PC + printer + bag + software),

3737

Configuration Scenarios: Order BOMs

Two-step process:1. Sales (VA01)f Header material is configured interactivelyf No Order BOM yet

2. Technical Order processing (Order BOM maintenance CU51)f Configuration of sub-levelsf Any component can be changed, deleted, copied, or addedf Order BOM created

One line in the Sales Order, and one (or more) new BOMs with reference to the line item (Order BOMs)

Pricing at header material level only Examples:

More complex Made-To-Order items, such as heavy machinery, aircraft, configurable kitchens, etc.

3838

Configuration Scenarios: More on Order BOMs

Two ways of saving the configuration results: Knowledge-based: f Super BOM + value assignment + Object dependencies +

manual changesf Performance-intensive

Result-oriented: f Order BOM + manual changes

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39

Configuration Scenarios: More on Order BOMs (cont.)

Other settings: Automatic Fixing: Create Order BOM after configuration in

Sales Order processing (vs. after technical processing, using CU51)

Maintenance in Order Allowed: Allows for technical processing during Sales Order

processing

4040

Configuration Scenarios: More on Order BOMs (cont.)

Fixing: Order BOMs are saved after technical processing (CU51) even

if no changes occurred Fixing parameters determines which assemblies in the BOM

structure you want to create order BOMs for Scope of fixing: selected assembly, top-down or bottom-up

Instantiation (result-oriented only): If the same configurable material occurs more than once in

the BOM structure (example: 2 DVD players in the PC), how do you differentiate (risk of confusion)?

Instantiation creates separate material master records Scope of instantiation: selected assembly, top-down, or

bottom-up

41

Configuration Scenarios: Summary

BOM EXPLOSION

Process None Single-level Multiple-level

Plnd/Prod. Order

Single-level (header) configurationBOM explosion (and dependencies for subs) in MRP onlyOne main item in Sales Order

Multi-level, interactive configuration (all items)Pricing at Header levelOne or more lines in Sales Order (linked to main item)No Order BOM

Sales Order (SET)

N/A

SET or KIT (example: PC package)Multi-level, interactive configuration (sales-relevant items only)Pricing at main item (header) or sub-item levelSeveral lines in Sales Order (linked to main item)No Order BOM

Order BOM N/A

Two-step process: Sales Order and BOM processingIn sales order, single-level configuration (standard) and no BOM explosionIn BOM maintenance, multi-level configuration, with manual changes possible (add, delete, or change items)Pricing at header level only

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4242

What Well Cover






4343

Planning for VC

Four main planning methods: Planning at Assembly level Standard product planning (characteristic-based planning) Assembly planning with characteristics planning Planning with planning variants

4444

Planning for VC: Planning at Assembly Level

Concepts: Typical Make-To-Order strategy Assembly is kept in stock Planned Independent Requirements entered at assembly

level When planned orders/production orders are created for the

finished product, dependent requirements/reservations are cleared against the Planned Independent Requirements

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4545

Planning for VC: Planning at Assembly Level (cont.)

Settings:

No forecast required for header material Where to get figures for assembly requirements Large data entry effort

AssemblyStrategy: 70

Assembly70

ConfigurableFinished product

Strategy: 25

Strategy: 70 Individual/collective requirements = 2 Mixed MRP indicator

Material Master

+

-

-

4646

Planning for VC: Standard Product Planning

Concepts: Planning is done at configurable product level (Planned

Independent Requirements) Non-convertible Planned Orders are created, with dependent

requirements for components according to usage probabilities of the characteristic values

Incoming Sales Orders consume the configurable materials independent requirements

47

Planning for VC: Standard Product Planning (cont.)

Settings: Strategy 56 for configurable product Create and maintain planning

(combination) tables (MDP1)f Same as variant tables

Create and maintain planning profiles (MDPH)f Which characteristics are

relevant to planning? Create planned independent

requirementsf Define planned frequency/usage

probability of characteristic values

Assembly Assembly


Strategy: 56

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4848

Planning for VC: Standard Product Planning (cont.)

Reduction of data entry effort Caution: depends on number of characteristics values

affecting planning Secondary requirements are consumed according to

values assigned in planning (not values in the Sales Order)

+

-

4949

Planning for VC: Assembly Processing with Characteristics Planning

Concepts: Same as previous strategy: Planning is done at configurable

product level (Planned Independent Requirements, or PIRs), based on characteristic (usage probability), except that the PIRs are inactive

Long-term planning is used to create dependent requirements for the assemblies

These dependent requirements are then activated (transferred from the planning scenario)

Therefore, the secondary requirements are consumed based on actual sales (vs. planned usage)

5050

Planning for VC: Assembly Processing with Characteristics Planning (cont.) Settings:

Strategy 89 for configurable product Strategy 70 for assembly

Create and maintain combination tables and planning profiles

Create and run long-term-planning scenario

Copy simulated dependent requirements (MS66) active dependent requirements

Incoming Sales Order Production Order Dependent Requirements consume Dependent Requirements in planning

AssemblyStrategy: 70

Assembly


Strategy: 89

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5151

Planning for VC: Assembly Processing with Characteristics Planning (cont.)

Advantages of all strategies Less planning effort, but more steps involved (Long-Term Planning) More precise consumption of planned requirements

+

-

+

+

5252

Planning for VC: Planning with Planning Variants

Concepts: Use material variants (e.g., a Make-to-Stock product based on a

specific configuration of a configurable material) Create Planned Independent Requirements for the planning

variants Dependent requirements are created for the assembly Incoming Sales Orders trigger Planned Independent

Requirement consumption based on Type Matching (weighting of characteristics)

53

Settings: Strategy 54 for the configurable material and the variants Assign characteristic values in MRP3 view of planning variant Define settings for Type Matching (see next slide) Maintain Planned Independent Requirements for planning

variants

53

Planning for VC: Planning with Planning Variants (cont.)

Assembly Assembly


54

Planning Variant I

54

Planning Variant II

54

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54

Planning for VC: Planning with Planning Variants (cont.)

Problem: If a Sales Order configuration

does not match a Planning Variant at 100%, which Planning Variant should the Planned Independent Requirements be consumed from?

Solution: Characteristics are given Weighting Factors in Type Matching

settings (transaction MDPV) The order consumes the planned requirements for the

planning variant with the highest sum of weightings

5555

What Well Cover






56

Engineering Change Management (ECM)

Variant Configuration object changes (Classes, Characteristics, BOMs, Routings, Dependencies, Configuration Profiles, etc.) can be managed with ECM

ECM will control and activate planned changes to the VC model through a Change Master Record (Change Number) or through Engineering Change Requests and Orders (ECR and ECO)

56

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5757

ECM and Order Change Management (OCM)

The Change Master Record (or ECR/ECO) controls: Which objects can be changed (specific objects) Valid-from date of the change Reason for changes Status

Planned changes can affect existing Sales Orders and production orders: You then need OCM

5858

OCM

Restriction: Effective change objects:

fMaterial BOMfOrder BOMfRouting

Not supported in OCM (up to ECC 5.0):fMaterial Master, Work Centers, changes to quantities or

dates in Sales Orders, Prerequisite (settings):

Overall change profile (in IMG) assigned to Material (Work Scheduling view)

Requirements Class must be EC mgt flagged (in IMG)

5959

OCM (cont.)

Process Sales Order or Master Data are changed using an ECM

Change Number Transaction COCM:

fDetermination of Production Orders affected by that change

Transaction COCM1:fSimulation of a Production Order (based on that change)fComparison with active production ordersf Identification of changes, check whether they are allowedfChange Production Orders

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6060

What Well Cover






6161

SCE/IPC: Overview

You need VC configuration methods to be available on the Internet or for field sales without being permanently online with SAP ERP (R/3 or SAP ECC)

SCE/IPC can be used as product configurator for Internet sales applications (online store, CRM scenarios) by synchronizing your modeling in ERP

It has a separate database and has open architecture (Java application, APIs)

It can therefore be integrated with third-party systems

6262

SCE/IPC: Architecture

Separation between user interface and configuration server:

SAP ERP or SAP CRM

Knowledge BasePricing Data

IPCSCE

Standard User Interface

Knowledge Base and Pricing

(IDoc)

SCE APIs

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6363

SCE/IPC: Process

Modeling in SAP R/3 or ECC Creating a knowledge-base object (CU31)

Collects all the information about a model:f Material master, BOM, classes,

characteristics, dependencies, A KB object is like a list of pointers to the

data required Creating one (or more) runtime versions

Based on a knowledge-base object Downloading the runtime version to the

SCE database Configuring in the SCE

6464

What Well Cover






6565

Performance

Performance can be an issue in VC models This section presents some hints and tips on how to

improve performance

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6666

Performance (cont.)

As few configuration levels as possible Keep configuration model small:

Several small models are better than a single large model Separate BOMs (to restrict the number of levels in the

BOM explosion in SD) For configuration in SD (application SD01), and For MRP and Production Order (application PP01)

In Task Lists (Routings): alternative sequences instead of several consecutive operations with the same selection conditions Assign the selection condition to the sequence May need a dummy operation in the standard sequence

67

Performance (cont.)

In the configuration profile: Restricts allowed screens on the interface design On request better than Permanent

6868

Performance (cont.)

Default values: quicker if defined in the characteristic than if set by dependencies

Class nodes (class item in BOM) Minimize number of characteristics If few materials, use separate material items (with

dependencies) instead of class nodes Using constraints:

Minimize the number of nets Use the CONDITION section Set up the CONDITION as disjunctive standard form

fExample: not a or not b (instead of not [a and b]) Use characteristic variables Enter whats really needed in the INFERENCES section

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6969

Performance (cont.)

Transparent tables instead of variant tables Create a custom transparent table Link variant table to database table Data transfer to database table

Define global dependencies if used more than once (local dependencies must be loaded several times)

Value check using function module, instead of: Preconditions Restrictable characteristics with constraints Variant tables

Do not mix procedures (actions) and constraints (value inferences should not influence each other)

7070

Client Management

VC models are Master Data Master Data cannot be transported (DEV TEST QA PROD)

How do you (safely) change your models? Set up a VC Golden Client, containing all the objects

relevant to VC Transport data using data distribution with Application Link

Enabling (ALE)f Using SAP standard Message Types (IDocs)f Transport sequence predetermined

7171

VC Projects: Modeling Guidelines

What are the products? One product with millions of variants? Millions of products without variants? A middle way?

Single-level or multi-level? Can lower-level configurable materials be determined from the

configuration of the header material? Modeling tips

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7272

VC Projects: Modeling Guidelines (cont.)

Customer viewpoint vs. production viewpoint Kitchen example: f Production looks at the individual closetsf Closets are assembled at customer premisesf The Kitchen level is not relevant to production

Characteristics what not to do: Two (or more) characteristics representing the same attributef Example: One characteristic for horsepower, one for

kilowatt Although, different allowed values or meanings in one

characteristicf Example: The length of a ship and the length of a

microprocessor must not be represented by the same characteristic

73

What Well Cover






7474

Resources

help.sap.com SAP Help Enterprise Central Component Logistics

Logistics General (LO) Variant Configuration (LO-VC) http://help.sap.com/saphelp_erp2005/helpdata/en/92/58d45541

7011d189ec0000e81ddfac/frameset.htm Configuration Workgroup (CWG)

SAP VC User Group www.configuration-workgroup.com

SAP Notes: 148778 and 502425: Header/component combination of

scenarios 660269: Error in Help

SAP PLM146 course Variant Configuration: Scenarios and Enhancements

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material configurable sap

Documents

variant pricing sd

vc engineering

sap vc

material mastermaterial

internet pricing

client management

advanced planning

length12possible values