Production Planning

Work Centers for Fitter SnackerR

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(100

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Mixer

Mixer

Mixer

Form Bake Pack

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Snack Bar Line

Production (200)

Production Master Data

CompanyCode

ValuationArea

Plant

MaterialMaster

WorkCenter

Bill of Material

RoutingCapacityPlanning

ProductionOrders

ProductCosting

Navigating Material Master Views

Click on tabs to selectUse direction arrows to scroll Use icon to get list

Material Types

A Material Type is used to classify materials: Defines material attributes like:

Valuation (value of material as market changes)Procurement (internal, external or both)

Controls screen sequence and number assignment Can restrict access using authorization groups A number of material types are pre-defined

Abbreviations are abbreviations of German terms Users can create their own material types

Usually best to copy a pre-defined type, then modify

Material Types in Exercises

ROH: Raw material Externally purchased only, no sales view Oats, Wheat Germ, Honey, Cinnamon, etc.

HALB: Semifinished Product No purchase or sales view Dough for NRG-A and NRG-B bars

FERT: Finished Product Produced internally, has sales views, no purchasing

views NRG-A and NRG-B bars

Other Material Types

HAWA: Trading Goods HIBE: Operating Supplies VERP: Customer returnable packaging LEER: Empty containers KMAT: Configurable material ERSA: Spare parts DIEN: Services NLAG: Non-stock, non-valuated material UNBW: Non-valuated, stocked material FHMI: Production resources/tools WETT: Competitive products PROD: Product group IBAU: Maintenance assembly

Documentation in Material Master

The SAP R/3 system documents all changes to the material master:

Click for documentation

Documentation in Material Master

Master Data – Bill of Material

BOMs are represented as single-level relationships between a material and its components and sub-assemblies

## NRG–A(case)

## Dough NRG–A(lb)

## Oats(lb)

## Wheat Germ(lb)

## Cinnamon(lb)

## Nutmeg(lb)

## Cloves(lb)

## Honey(gal)

## Vit/Min Powder(lb)

## Carob Chips(lb)

## Raisins(lb)

## Canola(gal)

BOM for NRG-A

BOM for Dough NRG-A

Routings

Routings define the relationship between a material and the sequence of workcenters (operations) that are required to produce the material

Also specifies where sub-components and sub-assemblies are needed in producing the material

2010 30 40 50 60

Functions of Production Orders(part 1 of 2)

Status Management: Tracking, User-defined status Scheduling Calculation of Capacity Requirements (detailed) Costing/Collection of Costs Availability Checks (material, capacity, PRT-

production resources and tools) Printing of Paper Orders/related documents

Assembly drawings and instructions Inspection instructions Storage regulations

Material Staging: withdrawal of materials used in production, e.g. components and sub-assemblies

Confirmations: quantities, activities, times Goods receipt: receipt of completed materials Period-end closing: Process cost allocation, overhead

costs, surcharges, WIP (work-in-process) calculation, variance calculation, order settlement

Archiving and retrieval Many more: rework, serial numbers, as-built, quality

control, etc.

Production Orders capture actual data—costs, dates, etc.

Functions of Production Orders(part 2 of 2)

Status Management(part 1 of 2)

Status Management is one tool that can be used to manage released production orders

A status can allow, allow with warning, or block a business transaction

Two status types are available System status: internal, predefined, fixed number User status: freely definable, set by user

Status Status detail

Status Management(part 1 of 2)

Planned Orders vs. Production Orders

Planned Orders are for PLANNING Production Orders are for EXECUTION

Planned Order 3 weeks in future

Planned Orders 2 weeks in future

Planned Orders 1 week in future

Production Orders released today

Planning

Execution

Master Data for Production Orders

Master Data is data that does not change frequently Master Data for the production order comes from:

Material Master Bill of Material (BOM) Work Center Routing Production Resources/Tools (PRT)

Materials like gages, fixtures, test equipmentCan also be items like drill bits that can be

consumed in production but aren’t consumed INTO the product

Most Production Order data comes from BOM and Routing

1

Order Request

2Order Creation

3

AvailabilityChecks

MachineReservation

4

Order Release5

6

Print Order7

Download toPDC system

8

Material staging9

Material withdrawalposting

10Upload fromPDC system

11

VarianceCalculation

Confirmation

12WIPDetermination

13Goods Receipt

14

15

Ordersettlement

16

Archiving &Deletion

ProductionOrderCycle

Routing Selection

Different routings can be selected for a product depending on a number of criteria like: Raw material used Lot size Product features/configurations (variants)

A complicated, automatic selection process can be configured

Bill of Material (BOM)

The system selects the FIRST Valid BOM it finds

Validity can depend on: Date (engineering changes) Customer Serial number

Material

Material Assignment

OP0010

OP0020

OP0030

OP0080

OP0090……..

Material

Mat

eria

lMaterial

OP0010

OP0020

OP0030

OP0080

OP0090……..

Material

Mat

eria

l

Assigned via BOM: All materials assigned to first operation

Assigned via Routing: Materials can be assignedto specific operations