pp-tscm42-2_unit 3

Unit 3: Repetitive Manufacturing

Lesson 1: Drafting Repetitive ManufacturingLesson 2: Preparing Repetitive ManufacturingLesson 3: Planning Line Loading in Repetitive ManufacturingLesson 4: Using Material Staging and ConfirmationLesson 5: Integrating Costing, Controlling, and Reporting

Lesson 1: Drafting Repetitive ManufacturingLesson ObjectivesAfter completing this lesson, you will be able to:

Outline the properties of repetitive manufacturing

TSCM42_2 Unit 3 Lesson 1

TSCM42_2 Figure 43: Application Areas Unit 3 Lesson 1

TSCM42_2 Figure 44: Repetitive Manufacturing: Characteristics

Unit 3 Lesson 1

TSCM42_2 Figure 45: Repetitive Manufacturing: Basic Functions

Unit 3 Lesson 1

TSCM42_2 Figure 46: Cross-Application Functional Process Unit 3 Lesson 1

TSCM42_2 Figure 47: Master Data for Repetitive Manufacturing

Unit 3 Lesson 1

TSCM42_2 Figure 48: Demo Scenario: PC Production in Dresden Plant

Unit 3 Lesson 1

Exercise 9: Check the Material Master of Repetitive Manufacturing.Business ExampleYou work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing.Therefore you first try to get a general overview of the basic master data for repetitive manufacturing.In particular, you focus on the following master data object: material masterVerify the Material MasterIn the Logistics folder in the SAP ECC menu, navigate to the material master of motherboard T-B10## (## represents your group number), plant 1200, and go to the MRP 4 view. Use the change mode (transaction MM02).

1. Navigate to the Material Master of motherboard T-B10## and go to the MRP 4, plant 1200 view.

TSCM42_2 Unit 3 Exercise 9

Exercise 9: Check the Material Master of Repetitive Manufacturing.

2. Name the basic material master settings that are specific to repetitive manufacturing.____________________________________________________________________________________________________________________________________________________________

3. Ensure that the Repetitive manufacturing profile 0001 is used for your material T-B10## in plant 1200. Do not leave the transaction.

4. Display production version 0001 and perform a consistency check on the combination of BOM and routing.

5. Which production line is entered in production version 0001?________________________________________________________________________________________________________


Exercise 9: Check the Material Master of Repetitive Manufacturing.

6. Write down the task list group of the rate routing entered and save your changes to the material master.________________________________________________________________________________________________________


Solution 9: Check the Material Master of Repetitive Manufacturing.Business ExampleYou work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing.Therefore you first try to get a general overview of the basic master data for repetitive manufacturing.In particular, you focus on the following master data object: material masterVerify the Material MasterIn the Logistics folder in the SAP ECC menu, navigate to the material master of motherboard T-B10## (## represents your group number), plant 1200, and go to the MRP 4 view. Use the change mode (transaction MM02).

1. Navigate to the Material Master of motherboard T-B10## and go to the MRP 4, plant 1200 view.

TSCM42_2 Unit 3 Solution 9

Solution 9: Check the Material Master of Repetitive Manufacturing.

a) SAP ECC menu path: Logistics Production Master data Material Master Material Change Immediately (MM02)

b) Enter your material number T-B10##, and choose Select Views.c) Select MRP 4 view and select Organizational levels.d) Enter plant 1200 and select Continue.

2. Name the basic material master settings that are specific to repetitive manufacturing.____________________________________________________________________________________________________________________________________________________________a) Repetitive mfg indicator, Repetitive manufacturing profile, Production version



3. Ensure that the Repetitive manufacturing profile 0001 is used for your material T-B10## in plant 1200. Do not leave the transaction.a) Change the REM profile to 0001 on the MRP4 view.

4. Display production version 0001 and perform a consistency check on the combination of BOM and routing.a) On the MRP 4 view select ProdVersions.b) Double click on version 0001.c) On the detail view for the production version, choose Check in the top right-

hand corner. The consistency check has the following results:BOM and routing exist. There are no error messages.Exit the screen by choosing Cancel.



5. Which production line is entered in production version 0001?________________________________________________________________________________________________________a) From the detail screen of the production version, you can see that production

version 0001 contains production line T-L3##.6. Write down the task list group of the rate routing entered and save your changes to

the material master.________________________________________________________________________________________________________a) The number varies. On the detail screen of the production version, the Task list

group is also displayed in the Rate-based planning line under Planning data.


Exercise 10: Check the Bill of Material of Repetitive Manufacturing.Business ExampleYou work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing .Therefore you first try to get a general overview of the basic master data for repetitive manufacturing.In particular, you focus on the following master object: BOM (bill of material)Verify the Bill of Material

1. Display your bill of material for T-B10## at plant 1200 with a BOM usage of 1.2. How many assemblies are on the hierarchy level directly below the finished

product? Finally, leave the transaction.____________________________________________________


Exercise 10: Check the Bill of Material of Repetitive Manufacturing.

____________________________________________________


Solution 10: Check the Bill of Material of Repetitive Manufacturing.Business ExampleYou work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing .Therefore you first try to get a general overview of the basic master data for repetitive manufacturing.In particular, you focus on the following master object: BOM (bill of material)Verify the Bill of Material

1. Display your bill of material for T-B10## at plant 1200 with a BOM usage of 1.a) SAP ECC menu path: Logistics Production Master data Bills of

materials Bill of material Material BOM Display (CS03)b) Enter material T-B10##, plant 1200, and BOM usage 1.


Solution 10: Check the Bill of Material of Repetitive Manufacturing.

c) Choose ENTER to enter the component overview.2. How many assemblies are on the hierarchy level directly below the finished

product? Finally, leave the transaction.________________________________________________________________________________________________________a) The Asm assembly indicator is set for one BOM item.


Exercise 11: Check the Routing of Repetitive Manufacturing.Business ExampleYou work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing .Therefore you first try to get a general overview of the basic master data for repetitive manufacturing.In particular, you focus on the following master object: RoutingVerify the Routing

1. Display the rate routing for material T-B10##, plant 1200 in the Logistics master data.

2. How many different routings are displayed in the overview?________________________________________________________________________________________________________


Exercise 11: Check the Routing of Repetitive Manufacturing.

3. Select the first routing with group counter 1 and choose the Operations button. What is special about the routing?________________________________________________________________________________________________________

4. Name the work center involved and the production rate for the routing.________________________________________________________________________________________________________

5. Exit the operation overview and go back to the rate routing overview and view the second routing.

6. Which work center belongs to group counter 2?____________________________________________________

7. View routing header data by choosing the Header button to show the task list group number.


Exercise 11: Check the Routing of Repetitive Manufacturing.

________________________________________________________________________________________________________

8. Does production version 0001 enable repetitive manufacturing with the two routings? Why (not)?________________________________________________________________________________________________________


Solution 11: Check the Routing of Repetitive Manufacturing.Business ExampleYou work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing .Therefore you first try to get a general overview of the basic master data for repetitive manufacturing.In particular, you focus on the following master object: RoutingVerify the Routing

1. Display the rate routing for material T-B10##, plant 1200 in the Logistics master data.a) SAP ECC menu path: Logistics Production Master

data Routings Routings Rate routings Display (CA23)b) Enter your material T-B10## and plant 1200 only.


Solution 11: Check the Routing of Repetitive Manufacturing.

c) Choose ENTER.2. How many different routings are displayed in the overview?

________________________________________________________________________________________________________a) Two routings exist (two group counters).

3. Select the first routing with group counter 1 and choose the Operations button. What is special about the routing?________________________________________________________________________________________________________a) In the rate routing overview, select the line with group counter and choose

Operations. The special feature here is that there is only one operation.4. Name the work center involved and the production rate for the routing.

____________________________________________________



____________________________________________________a) The work center contains the (entire) T-L3## line and the production rate (30

pieces per hour).5. Exit the operation overview and go back to the rate routing overview and view the

second routing.a) In this transaction choose menu path Goto Routing Overview. Select only the

line with group counter 2 and choose the Operations button.6. Which work center belongs to group counter 2?

____________________________________________________a) The work center used in the second routing is T-L4## as well as reporting

points LINE4-1, LINE4-2, and LINE4-3.7. View routing header data by choosing the Header button to show the task list

group number.



________________________________________________________________________________________________________a) View the task list group number. The task list group number is the same as

noted before when analyzing the production version.8. Does production version 0001 enable repetitive manufacturing with the two

routings? Why (not)?________________________________________________________________________________________________________a) No. Production version 0001 only allows production according to the routing

with group counter 1. Leave the transaction using the Back button.


Exercise 12: Check the Product Cost Collector of Repetitive Manufacturing.Business ExampleYou work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the SAP SCM project team responsible for implementing the functions of Repetitive Manufacturing .Therefore you first try to get a general overview of the basic master data for repetitive manufacturing.In particular, you focus on the following master object: Product cost collectorVerify the Product Cost Collector

1. Display the product cost collectors, using the Repetitive Manufacturing menu, for material T-B10## in plant 1200.

2. How many product cost collectors exist and how are they assigned? Finally, leave the transaction.


Exercise 12: Check the Product Cost Collector of Repetitive Manufacturing.

____________________________________________________________________________________________________________________________________________________________


Solution 12: Check the Product Cost Collector of Repetitive Manufacturing.Business ExampleYou work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the SAP SCM project team responsible for implementing the functions of Repetitive Manufacturing .Therefore you first try to get a general overview of the basic master data for repetitive manufacturing.In particular, you focus on the following master object: Product cost collectorVerify the Product Cost Collector

1. Display the product cost collectors, using the Repetitive Manufacturing menu, for material T-B10## in plant 1200.


Solution 12: Check the Product Cost Collector of Repetitive Manufacturing.

a) SAP ECC menu path: Logistics Production Repetitive manufacturing Master data Product Cost Collector Process Product Cost Collector (KKF6N)

b) Enter material number T-B10## and plant 1200 and choose ENTER.c) In the upper left part of the screen, select material T-B10##. Expand the

selection.2. How many product cost collectors exist and how are they assigned? Finally, leave

the transaction.____________________________________________________________________________________________________________________________________________________________


Solution 12: Check the Product Cost Collector of Repetitive Manufacturing.

a) Two product cost collectors exist. They are assigned to the material by means of the production version (one product cost collector for each production version). Leave the transaction using the Back button.


SummaryYou should now be able to:

Outline the properties of repetitive manufacturing

TSCM42_2

Lesson 2: Preparing Repetitive ManufacturingLesson ObjectivesAfter completing this lesson, you will be able to:

Prepare repetitive manufacturing with regard to planning


TSCM42_2 Figure 49: Repetitive Manufacturing: Process Flow

Unit 3 Lesson 2

TSCM42_2 Figure 50: Planning in Repetitive Manufacturing Unit 3 Lesson 2

TSCM42_2 Figure 51: Basic Planning Strategies for Repetitive Manufacturing

Unit 3 Lesson 2

Exercise 13: Verify Material Master Settings for Repetitive Manufacturing.Business ExampleYou manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program.First, check whether the master data for material T-B10## (motherboard) is correct.Check the Material Master SetupBefore you can run MRP you must assure yourself that master data is in place for repetitive manufacturing.

1. Is the material T-B10## (the motherboard) in plant 1200 permitted for repetitive manufacturing?________________________________________________________________________________________________________

2. Is there a repetitive manufacturing profile maintained on the same view?


Exercise 13: Verify Material Master Settings for Repetitive Manufacturing.

________________________________________________________________________________________________________

3. Finally, check the existing production versions: Is the REM allowed indicator set?____________________________________________________


Solution 13: Verify Material Master Settings for Repetitive Manufacturing.Business ExampleYou manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program.First, check whether the master data for material T-B10## (motherboard) is correct.Check the Material Master SetupBefore you can run MRP you must assure yourself that master data is in place for repetitive manufacturing.

1. Is the material T-B10## (the motherboard) in plant 1200 permitted for repetitive manufacturing?________________________________________________________________________________________________________


Solution 13: Verify Material Master Settings for Repetitive Manufacturing.

a) Check whether the repetitive manufacturing indicator is set in the MRP 4 view. It has been set.

2. Is there a repetitive manufacturing profile maintained on the same view?________________________________________________________________________________________________________a) Yes, either repetitive manufacturing profile 0002 or 0001 is maintained on the

MRP 4 view.3. Finally, check the existing production versions: Is the REM allowed indicator set?

____________________________________________________a) Yes. Select the ProdVersions icon on the MRP 4 view and display the

production versions one after the other to view the indicator. When complete,


Solution 13: Verify Material Master Settings for Repetitive Manufacturing.

save (or leave the transaction via the Back button if you haven't changed anything).


Exercise 14: Create a Production Program for Repetitive Manufacturing.Business ExampleYou manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program.Create a production program for material T-B10## (motherboard).Maintain Planned Independent Requirements

1. Manufacturing is unsure of the accuracy of the sales department forecasts for the upcoming months for your personal computers. However, operations wants to hedge sales by putting a forecast in at the sub-assembly level. Enter 1200 PC for next week for your material T-B10## at plant 1200 in version 00, and activate the demand plan for MRP. Before saving the results split the weekly demand into daily buckets.


Solution 14: Create a Production Program for Repetitive Manufacturing.Business ExampleYou manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program.Create a production program for material T-B10## (motherboard).Maintain Planned Independent Requirements

1. Manufacturing is unsure of the accuracy of the sales department forecasts for the upcoming months for your personal computers. However, operations wants to hedge sales by putting a forecast in at the sub-assembly level. Enter 1200 PC for next week for your material T-B10## at plant 1200 in version 00, and activate the demand plan for MRP. Before saving the results split the weekly demand into daily buckets.


Solution 14: Create a Production Program for Repetitive Manufacturing.

a) SAP ECC menu path:Logistics Production Production Planning Demand Management Planned Independent Requirements Create (MD61)

b) Enter material T-B10##, plant 1200 and version 00, and set the planning period to W (weekly) buckets.

c) Choose ENTER.d) When you reach the planning table, enter the 1200 PC requirements in the

second weekly bucket.

Caution:Do not use the current week!


Solution 14: Create a Production Program for Repetitive Manufacturing.

e) Choose the Sched. Lines tab. The quantity with period indicator W is to be distributed over the individual working days. Therefore, set the Splt column indicator to D (day format) and confirm your entry.

f) Confirm any warning messages that may be displayed by selecting ENTER.g) When complete select Save.


Exercise 15: MRP in Repetitive Manufacturing.Business ExampleYou manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program.Carry out a multilevel MRP run for your material.Perform Material Requirements Planning

1. Plan the T-B10## at plant 1200 using an multilevel single-item MRP run. Use the default parameters that are set when you enter the transaction.

Hint:Multilevel planning ensures that dependent requirements are also generated for lower hierarchy levels in the BOM.


Exercise 15: MRP in Repetitive Manufacturing.

2. Interpret the results of the planning run for the T-B10## at plant 1200, using the stock/requirements list.

3. Review the details of your first planned order.4. What is the order type of the planned order?

____________________________________________________5. Can you convert this planned order to a production or process order? Why (not)?

Finally, leave the transaction.________________________________________________________________________________________________________


Solution 15: MRP in Repetitive Manufacturing.Business ExampleYou manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program.Carry out a multilevel MRP run for your material.Perform Material Requirements Planning

1. Plan the T-B10## at plant 1200 using an multilevel single-item MRP run. Use the default parameters that are set when you enter the transaction.

Hint:Multilevel planning ensures that dependent requirements are also generated for lower hierarchy levels in the BOM.


Solution 15: MRP in Repetitive Manufacturing.

a) SAP ECC menu path Logistics Production MRP Planning Multilevel Single-item planning (MD02)

b) Enter you material T-B10## and plant 1200.c) Choose ENTER twice to start the run.

2. Interpret the results of the planning run for the T-B10## at plant 1200, using the stock/requirements list.a) SAP ECC menu path: Logistics Production MRP Evaluations Stock/

Requirements List (MD04)b) Enter your material T-B10## and plant 1200, and choose ENTER.

3. Review the details of your first planned order.a) Double click on the first planned order.


Solution 15: MRP in Repetitive Manufacturing.

4. What is the order type of the planned order?____________________________________________________a) Planned order type LA - Stock Order

5. Can you convert this planned order to a production or process order? Why (not)? Finally, leave the transaction.________________________________________________________________________________________________________a) No - checking the details view of the planned order the conversion buttons are

missing. This is because of the REM flag in the material master MRP4 view. Leave the details of the planned order and the transaction via the Cancel and Back buttons, respectively.



Prepare repetitive manufacturing with regard to planning

TSCM42_2

Lesson 3: Planning Line Loading in Repetitive ManufacturingLesson ObjectivesAfter completing this lesson, you will be able to:

Plan line loading in repetitive manufacturing


TSCM42_2 Figure 52: Overview: Planning Line Loading Unit 3 Lesson 3

TSCM42_2 Figure 53: Actions for Manual Line Loading Planning (Example: ECC)

Unit 3 Lesson 3

Exercise 16: Perform Line Loading in Repetitive Manufacturing.Business ExampleTwo production lines are available for the assembly of the T-B10## motherboard. The basic dates as to quantities and periods have already been determined in MRP and production planning in the previous exercise. As the production planner, you now assign the quantities to the relevant production line.Assign the MRP Results to the Production LinesAs a result of the MRP run, planned orders have been created to cover the forecast requirements for your mother board T-B10## at plant 1200. Earlier you reviewed your master data and recognized that two production lines could manufacture the motherboard. In order for execution to take place we must decide what quantities are going to run on what lines taking capacity availability into account. Access the repetitive planning table and assign quantities to production lines.

1. Access the planning table for repetitive manufacturing. for your production line T-L3## and T-L4## in plant 1200. Make sure that you are scheduling using rate based planning; that capacity planning data is visible, and that all other production


Exercise 16: Perform Line Loading in Repetitive Manufacturing.

options are available for scheduling. Assign the planned orders to the production lines, taking into account the available capacities.

Note:Save your settings in order to speed up access during later reviews

2. Double-click a quantity in the planning table section that is ready for input to display the detail data for the planned order. Which order type is assigned (F4 help)?____________________________________________________

3. Change your user settings so the total requirements as well as supply is visible in the lower table.

4. Put the table in assignment mode to schedule the unassigned quantities in the planning table section that is ready for input. Assign the unassigned quantity to the final assembly line.


Exercise 16: Perform Line Loading in Repetitive Manufacturing.

5. Double-click the quantity you have just assigned. Which order type is now assigned (F4 help)?____________________________________________________

6. Look at the capacity data. Does the production line reach full capacity with the planned order in the relevant time interval or is some capacity still available for other orders in the same period?________________________________________________________________________________________________________

7. Save your planning results.


Solution 16: Perform Line Loading in Repetitive Manufacturing.Business ExampleTwo production lines are available for the assembly of the T-B10## motherboard. The basic dates as to quantities and periods have already been determined in MRP and production planning in the previous exercise. As the production planner, you now assign the quantities to the relevant production line.Assign the MRP Results to the Production LinesAs a result of the MRP run, planned orders have been created to cover the forecast requirements for your mother board T-B10## at plant 1200. Earlier you reviewed your master data and recognized that two production lines could manufacture the motherboard. In order for execution to take place we must decide what quantities are going to run on what lines taking capacity availability into account. Access the repetitive planning table and assign quantities to production lines.

1. Access the planning table for repetitive manufacturing. for your production line T-L3## and T-L4## in plant 1200. Make sure that you are scheduling using rate based planning; that capacity planning data is visible, and that all other production


Solution 16: Perform Line Loading in Repetitive Manufacturing.

options are available for scheduling. Assign the planned orders to the production lines, taking into account the available capacities.

Note:Save your settings in order to speed up access during later reviews

a) SAP ECC menu path: Logistics Production Repetitive Manufacturing Planning Planning Table Change Mode (MF50)

b) Enter the final assembly line T-L3## and select via Production line.c) In the Scheduling tab, make sure Rate-based Planning is selected, and capacity

planning is selected.d) In the Control tab, select Line Overview.e) Select Settings.



f) Select Planning Table.g) In the window that appears select all production lines and select Continue.

2. Double-click a quantity in the planning table section that is ready for input to display the detail data for the planned order. Which order type is assigned (F4 help)?____________________________________________________a) The planned order has order type LA Stock order. Choose the Cancel button to

leave the screen.3. Change your user settings so the total requirements as well as supply is visible in

the lower table.a) Select User Settings.b) Check Total Requirements check box.



c) Select Check Data.d) Select Adopt.

4. Put the table in assignment mode to schedule the unassigned quantities in the planning table section that is ready for input. Assign the unassigned quantity to the final assembly line.a) Select the line labeled Not Yet Assigned.b) Switch on the assignment mode using the push button with the truck icon.c) A symbol appears at the start of the line, signifying that you are in assignment

mode for this line.d) Assign the quantities in the Not yet assigned section. Enter the quantities in

one of the production line fields that belongs to the same period.



Note:Be sure to choose ENTER in order for the system to recalculate the available quantities and the capacity requirements.

e) Deactivate the assignment mode by choosing the according push button.5. Double-click the quantity you have just assigned. Which order type is now assigned

(F4 help)?____________________________________________________a) The planned order has the order type PE (run schedule quantity).

6. Look at the capacity data. Does the production line reach full capacity with the planned order in the relevant time interval or is some capacity still available for other orders in the same period?____________________________________________________



____________________________________________________a) By dispatching a planned order on production line T-L3##, the line only

reaches a comparatively low capacity load (see the planning table: Capacity data in the row for production line T-L3##). The capacity data is not available on the same day as the production quantities since the quantities are determined to the day according to availability, while the capacity load of the production line is determined tothe hour and minute according to the production date.

7. Save your planning results.a) Select Save.



Plan line loading in repetitive manufacturing

TSCM42_2

Lesson 4: Using Material Staging and ConfirmationLesson ObjectivesAfter completing this lesson, you will be able to:

Stage and confirm material in repetitive manufacturing


TSCM42_2 Figure 54: Material Staging Options Unit 3 Lesson 4

TSCM42_2 Figure 55: Backflush and Goods Receipt Unit 3 Lesson 4

TSCM42_2 Figure 56: Backflush: Reporting Point Backflush Unit 3 Lesson 4

Exercise 17: Perform Material Staging for Repetitive Manufacturing.Business ExampleFor assembly production of motherboard T-B10##, you want to check for missing components in the production storage location PL03 and use stock transfer measures to stage missing components for a certain production period.Carry out Material StagingNow that you have run MRP to cover your requirements and scheduled production to the appropriate lines, you need to ensure that the material is available to support production. In this section you will learn how material staging supports backflushing.

1. Execute the pull list for production line T-L3## in plant 1200, in order to stage the necessary components for production. The staging should be performed for line for all requirements that are received until Tuesday of the week after next. In this example, material staging is performed at storage location level. Some steps in the pull list can be carried out automatically, Create replenishment proposals and Batch/stock determination. Make the changes in global settings.


Exercise 17: Perform Material Staging for Repetitive Manufacturing.

2. Go to the pull list. Interpret the results of the automatic steps. For which materials are there shortfall quantities until Tuesday of the week after next due to the planned requirements? How large are these quantities?________________________________________________________________________________________________________

3. At which storage location are there shortfall quantities?________________________________________________________________________________________________________

4. At which storage location has the system found a replenishment quantity?____________________________________________________

5. Can the complete shortfall quantity be covered from here?____________________________________________________


Exercise 17: Perform Material Staging for Repetitive Manufacturing.

6. You accept the system proposal. To trigger material staging for the relevant components from warehouse 0001 to production storage location PL03.

7.Caution:Material staging (using direct stock transfer in this case) is not carried out until you save the pull list. If you need a printout of the list for the physical stock transfer, we recommend printing it before you save (Pull List Print). Save your results.

8. Check the stock transfer posting in the message log for the pull list (in a separate transaction).


Solution 17: Perform Material Staging for Repetitive Manufacturing.Business ExampleFor assembly production of motherboard T-B10##, you want to check for missing components in the production storage location PL03 and use stock transfer measures to stage missing components for a certain production period.Carry out Material StagingNow that you have run MRP to cover your requirements and scheduled production to the appropriate lines, you need to ensure that the material is available to support production. In this section you will learn how material staging supports backflushing.

1. Execute the pull list for production line T-L3## in plant 1200, in order to stage the necessary components for production. The staging should be performed for line for all requirements that are received until Tuesday of the week after next. In this example, material staging is performed at storage location level. Some steps in the pull list can be carried out automatically, Create replenishment proposals and Batch/stock determination. Make the changes in global settings.


Solution 17: Perform Material Staging for Repetitive Manufacturing.

a) SAP ECC menu path: Logistics Production Repetitive Manufacturing Material Staging Pull List - Trigger Replenishment (MF60)

b) Set the staging type to storage location level (SLoc Level).c) Enter plant 1200 and selection period Tuesday of the week after next.d) Enter production line T-L3## in the Plnd Orders area of the screen.e) Select Global Settings.f) In the Dialog Control tab set Create replenishment proposals and Execute

Batch/stock determination to Automatic.g) Select Continue.h) Select Execute.



2. Go to the pull list. Interpret the results of the automatic steps. For which materials are there shortfall quantities until Tuesday of the week after next due to the planned requirements? How large are these quantities?________________________________________________________________________________________________________a) Due to the planned requirements, there are shortfall quantities for material T-

T6## until Tuesday of the week after next. The system automatically created a replenishment proposal and determined stock for component T-T6## in storage location 0001. The pull list shows the size of the shortfall quantity.

3. At which storage location are there shortfall quantities?________________________________________________________________________________________________________



a) There are shortfall quantities at production storage location PL03, where the components for assembly production are to be staged.

4. At which storage location has the system found a replenishment quantity?____________________________________________________a) The replenishment quantity was found in central warehouse 0001.

5. Can the complete shortfall quantity be covered from here?____________________________________________________a) Yes, the staging quantity is equal to the shortfall quantity.

6. You accept the system proposal. To trigger material staging for the relevant components from warehouse 0001 to production storage location PL03.a) Select the row with the replenishment element and select Stage.



7.Caution:Material staging (using direct stock transfer in this case) is not carried out until you save the pull list. If you need a printout of the list for the physical stock transfer, we recommend printing it before you save (Pull List Print). Save your results.

a) Select Save.8. Check the stock transfer posting in the message log for the pull list (in a separate

transaction).a) SAP ECC menu path: Logistics Production Repetitive

Manufacturing Material Staging Log (MF68)The stock transfer was successfully posted in the system.



b) Access the log from the Material Staging menu, enter today's date as the To date, and choose Execute.Finally, leave the transaction using the Back button.


Exercise 18: Confirm Production Quantities in Repetitive Manufacturing.Business ExampleNow that scheduling is complete and materials have been staged at the production line production is ready to execute. In this section you will learn how backflushing is managed in SAP ECC.Carry out Confirmation

1. First, open a second session of the planning table for repetitive manufacturing (which you access by selecting production line T-L3##, plant 1200).

2. In the first session, execute a REM confirmation for 90 pieces of the motherboard material T-B10## produced on line T-L3## in plant 1200. Then choose Post with correction .

3. Look at the next screen and explain which components of assembly T-B10## were backflushed on the line. Save.


Exercise 18: Confirm Production Quantities in Repetitive Manufacturing.

4. Go to the second session (planning table). Refresh the screen and look at the quantities on the line.

5. How have the planned quantities changed?________________________________________________________________________________________________________


Solution 18: Confirm Production Quantities in Repetitive Manufacturing.Business ExampleNow that scheduling is complete and materials have been staged at the production line production is ready to execute. In this section you will learn how backflushing is managed in SAP ECC.Carry out Confirmation

1. First, open a second session of the planning table for repetitive manufacturing (which you access by selecting production line T-L3##, plant 1200).a) Select System Create Session to open a new session and use the following

path:b) SAP ECC menu path: Logistics Production Repetitive

Manufacturing Planning Planning Table Change Mode (MF50)c) Enter plant 1200 and production line T-L3## and choose ENTER.


Solution 18: Confirm Production Quantities in Repetitive Manufacturing.

Note:The settings have defaulted in from a previous exercise step.

d) Select Execute Planning Table, select all production lines and confirm to enter the table.

2. In the first session, execute a REM confirmation for 90 pieces of the motherboard material T-B10## produced on line T-L3## in plant 1200. Then choose Post with correction .a) SAP ECC menu path: Logistics Production Repetitive

Manufacturing Data Entry Repetitive Manufacturing Confirmation (MFBF)b) Enter the following data on screen of the backflush transaction screen:



The production version contains the production on line T-L3##.Choose ENTER and choose Post with correction.

3. Look at the next screen and explain which components of assembly T-B10## were backflushed on the line. Save.a) The current BOM was exploded during the confirmation. The system

determined the materials to be backflushed in the BOM explosion. The all or nothing principle applies, which means that all four materials displayed are backflushed.

4. Go to the second session (planning table). Refresh the screen and look at the quantities on the line.a) Select the other open session of SAP ECC.b) Use menu path from here: Planning Reaccess



5. How have the planned quantities changed?________________________________________________________________________________________________________a) The first planned order quantity is (or quantities are) reduced according to the

confirmation quantity. Explanation: For demonstration purposes, the backflush was made with a date (today) that is before the actual production dates. The confirmation quantity is therefore interpreted as over-production that reduces subsequently planned orders accordingly (first planned orders first).



Stage and confirm material in repetitive manufacturing

TSCM42_2

Lesson 5: Integrating Costing, Controlling, and ReportingLesson ObjectivesAfter completing this lesson, you will be able to:

Outline the integration of costing, controlling, and reporting to repetitive manufacturing


TSCM42_2 Figure 57: Cost Debit/Credit (Product-Related Cost Object Controlling)

Unit 3 Lesson 5

TSCM42_2 Figure 58: Integration with Controlling Unit 3 Lesson 5

TSCM42_2 Figure 59: Repetitive Manufacturing: Information Systems

Unit 3 Lesson 5

TSCM42_2 Figure 60: Period-Based Repetitive Manufacturing: Additional Functions

Unit 3 Lesson 5


Outline the integration of costing, controlling, and reporting to repetitive manufacturing

TSCM42_2

Name some basic functions of repetitive manufacturing.

TSCM42_2 Open Question Unit 3

Name some basic functions of repetitive manufacturing..Planning line loading, Scheduling, Calculation and monitoring of capacity requirements, Costing, Avaiability checks, Printing dispatch lists, Printing operational method sheet, Material staging, Goods issue/backflushing, Goods receipt with final confirmation, Period-end closing.


Why do you need a material cost estimate to calculate production activities in repetitive manufacturing?


Why do you need a material cost estimate to calculate production activities in repetitive manufacturing?.Due to the handling of production quantities with planned orders there is no real "order" object to collect and carry the production activities. This is covered by a material cost estimate and subsequent price update in the material master.


Course OverviewUnit 1: Introduction to Production ExecutionLesson 1: Distinguishing Production TypesFigure 1: SAP ERP Application OverviewFigure 2: SAP SCM Application OverviewFigure 3: SAP Components for Supply Chain ManagementFigure 4: Production Types for ProductionFigure 5: Production Type for Material FlowSummary

Open Question

Unit 2: Production with Process OrdersLesson 1: Drafting Process OrdersFigure 6: Application Areas of Process OrdersFigure 7: Process Order-Controlled Production: CharacteristicsFigure 8: Process Order-Controlled Production: Basic FunctionsFigure 9: Process Order-Controlled Production: Connection to Process Control LevelFigure 10: Cross-Application Functional ProcessProcedure: To Work with Process OrdersFigure 11: Master Data for Process OrdersFigure 12: Material and BatchFigure 13: Batch Management in Supply Chain ManagementFigure 14: Demo Scenario: Ice Cream Production in Plant 1100Exercise 1: Analyze Master Data of Process OrdersSummary

Lesson 2: Creating and Interpreting Process OrdersFigure 15: Processing a Process OrderFigure 16: Structure of the Process OrderFigure 17: Elements of the Process OrderFigure 18: Order Creation OptionsFigure 19: Integration with Planning (SAP ECC or SAP SCM-APO)Figure 20: Order Creation with Planned OrdersFigure 21: Batch DeterminationExercise 2: Process Planning for Process OrdersExercise 3: Evaluate the Results of MRPExercise 4: Create Process Orders by Conversion of Planned OrdersExercise 5: Evaluate Details of the Process OrderSummary

Lesson 3: Executing Process OrdersFigure 22: Order Release FunctionsFigure 23: Detailed Planning on Work CentersFigure 24: Example: Graphical Planning TableFigure 25: Availability Checks (Material, Capacity)Figure 26: Process ManagementExercise 6: Release a Process OrderFigure 27: HTML-based PI Sheet IFigure 28: HTML-based PI Sheet IIFigure 29: The Material Staging ProcessFigure 30: Standard Postings for Process OrdersFigure 31: Process Order: Goods Issue PostingFigure 32: Confirmations OverviewFigure 33: Types of ConfirmationsFigure 34: Flexible Data Entry with Process MessagesFigure 35: Functions for production in compliance with GMPFigure 36: Production in Compliance with GMPExercise 7: Execute a Process Order Using the PI SheetExercise 8: Review the Results of Execution on Production PlanningSummary

Lesson 4: Using Additional Functions with Process OrdersFigure 37: Enhanced Functions for Process OrderFigure 38: Material Quantity CalculationFigure 39: Resource Network and Resource SelectionFigure 40: Batch DerivationFigure 41: Process Manufacturing: Information SystemsFigure 42: Batch Where-Used ListSummary

Open QuestionOpen QuestionOpen QuestionOpen QuestionOpen Question

Unit 3: Repetitive ManufacturingLesson 1: Drafting Repetitive ManufacturingFigure 43: Application AreasFigure 44: Repetitive Manufacturing: CharacteristicsFigure 45: Repetitive Manufacturing: Basic FunctionsFigure 46: Cross-Application Functional ProcessFigure 47: Master Data for Repetitive ManufacturingFigure 48: Demo Scenario: PC Production in Dresden PlantExercise 9: Check the Material Master of Repetitive ManufacturingExercise 10: Check the Bill of Material of Repetitive ManufacturingExercise 11: Check the Routing of Repetitive ManufacturingExercise 12: Check the Product Cost Collector of Repetitive ManufacturingSummary

Lesson 2: Preparing Repetitive ManufacturingFigure 49: Repetitive Manufacturing: Process FlowFigure 50: Planning in Repetitive ManufacturingFigure 51: Basic Planning Strategies for Repetitive ManufacturingExercise 13: Verify Material Master Settings for Repetitive ManufacturingExercise 14: Create a Production Program for Repetitive ManufacturingExercise 15: MRP in Repetitive ManufacturingSummary

Lesson 3: Planning Line Loading in Repetitive ManufacturingFigure 52: Overview: Planning Line LoadingFigure 53: Actions for Manual Line Loading Planning (Example: ECC)Exercise 16: Perform Line Loading in Repetitive ManufacturingSummary

Lesson 4: Using Material Staging and ConfirmationFigure 54: Material Staging OptionsFigure 55: Backflush and Goods ReceiptFigure 56: Backflush: Reporting Point BackflushExercise 17: Perform Material Staging for Repetitive ManufacturingExercise 18: Confirm Production Quantities in Repetitive ManufacturingSummary

Lesson 5: Integrating Costing, Controlling, and ReportingFigure 57: Cost Debit/Credit (Product-Related Cost Object Controlling)Figure 58: Integration with ControllingFigure 59: Repetitive Manufacturing: Information SystemsFigure 60: Period-Based Repetitive Manufacturing: Additional FunctionsSummary

Open QuestionOpen Question

Unit 4: The Kanban PrincipleLesson 1: Drafting KanbanFigure 61: Application AreasFigure 62: Kanban PrincipleFigure 63: Kanban: CharacteristicsSummary

Lesson 2: Using Kanban in ProductionFigure 64: Using Kanban in ProductionFigure 65: Master Data: Production Supply AreaFigure 66: Master Data: Kanban Control CycleFigure 67: Production Supply Using Control CyclesFigure 68: Setting the Kanban to Empty = Triggering ReplenishmentFigure 69: Setting Kanban to Full = Posting Goods ReceiptFigure 70: Plan-Controlled Production versus KanbanExercise 19: Check a Kanban MaterialExercise 20: Check the Kanban Control CycleExercise 21: Proceed Kanban ExecutionSummary

Open QuestionOpen QuestionOpen QuestionOpen QuestionOpen Question

Unit 5: Capacity Requirements Planning (ERP)Lesson 1: Introducing Capacity Requirements PlanningFigure 71: Capacity Planning EnvironmentFigure 72: Capacity Planning and ElementsFigure 73: Display TypesSummary

Lesson 2: Evaluating CapacityFigure 74: Capacity EvaluationFigure 75: Overall ProfileFigure 76: Standard OverviewFigure 77: Selection and Display ParametersFigure 78: Detailed Capacity List and Its FunctionsFigure 79: Capacity Planning EnvironmentFigure 80: Capacity Requirements CalculationFigure 81: Setting Up a FormulaFigure 82: Capacity Load ReductionFigure 83: Methods of Capacity ReductionExercise 22: Use the Standard OverviewSummary

Lesson 3: Leveling Capacity in the Tabular Planning TableFigure 84: Capacity Leveling MethodsFigure 85: Mass ProcessingFigure 86: Tabular Capacity Planning TableFigure 87: Dispatching ProcedureFigure 88: Finite SchedulingFigure 89: Time ProfileFigure 90: Dispatching Variants (Tabular)Exercise 23: Use the Tabular Capacity Planning TableSummary

Lesson 4: Maintaining Available CapacityFigure 91: Work Center DataFigure 92: Available Capacity at a Work CenterFigure 93: Using Key Shift Sequences to Maintain Available CapacitySummary

Lesson 5: Leveling Capacity in the Graphical Planning TableFigure 94: Graphical Capacity Planning TableFigure 95: Capacity Leveling Overall ProfileFigure 96: Structure of a Profile (Leveling)You carry out the following steps when dispatching operations:Figure 97: Strategy profileFigure 98: Midpoint Scheduling Dispatched OperationFigure 99: Midpoint Scheduling Scheduling a Second OperationExercise 24: Apply Planning Strategies in the Graphical Planning TableSummary

Lesson 6: Evaluating Capacity Using Business IntelligenceFigure 100: Overview of Business IntelligenceFigure 101: 0PP_C13 Capacity Utilization Data FlowThe delivered queries come with the following master data (characteristics) for reporting:You can also take advantage of other fields, such as the following fields, for reporting purposes:Delivered queries can be distributed over the following time periods:Delivered queries present the following data:The Capacity Load Utilization InfoCube has several standard queries, such as the following queries:Figure 102: 0PP_13_Q001 Capacity Load Utilization (Distributed Requirements)Figure 103: 0PP_C13 Capacity Utilization QueryExercise 25: Use BI to Perform Capacity EvaluationSummary

Multiple ChoiceMultiple ChoiceTrue FalseMultiple ChoiceMultiple ChoiceMultiple ChoiceMultiple ChoiceMultiple ChoiceTrue FalseMultiple ChoiceTrue FalseMultiple ChoiceMultiple ChoiceMultiple ChoiceMultiple ChoiceTrue FalseMultiple ChoiceMultiple ChoiceMultiple ChoiceMultiple ChoiceTrue FalseMultiple ChoiceMultiple ChoiceMultiple Choice

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