PI Sheets for ManufacturingDocument Information

Note: All dates in this document should be using the format DD. Month YYYY (e.g. 21. May 2001).

Important Note: This guideline is still in draft form and several sections will be revised when Integration Testing 1 and 2 are completed.

GENERAL INFORMATION

Organization FC-EARTH/GT

Associated Documentation

GT_Guideline_Matconsumption_manufacturing.doc

Author John Gallagher

REVIEW / APPROVAL

Function Dept. Approved by Date

Rev

iew Name:_______________________

Signature:_____________________

(Format DD. Month YYYY)

Ap

pro

val Name:_______________________

Signature:_____________________

(Format DD. Month YYYY)

Version Reason for Change Guideline Effective Date

1 in case there is a change the GTC document has to be named and / or referenced here

Date from when the change is effective

Data Guideline Specification

DATA FIELD GUIDELINE

Description of the Data Field.The PPPI Process Instruction sheet in SAP requires the following configuration & master data objects:

- Master Recipe- Resource- Process Instructions- Production Supply Areas- Control Cycle Records- BOM- Control Recipe Destinations

Data Guideline Explanation The intention with this guideline is to assist the implementation team on the various Tokyo sites going live with EARTH Template version1 on how to structure the master data to create PI Sheets for consumption, receipts and confirmations.

Applicable SAP field(s)

REASON FOR DATA GUIDELINE

Reason for introduction of this Data Guideline.The current configuration for EARTH Template offers multiple options for batch and storage unit management of materials is fairly complex and requires a full understanding of the master data to generate PI Sheets with the appropriate facilities for material receipts, consumption and order confirmations.

This guideline gives an outline of the different options available for the PI Sheet and the master data needed for their generation. This guideline should be read in conjunction with the guideline for material consumption and warehouse storage locations.

DEPENDENCIES

Dependencies from.GT_Guideline_Storagelocation_Warehouse.docGT_Guideline_Matconsumption_manufacturing.doc

Dependencies to.

Table of Contents

1 Material Handling Options for Production_________________________________________6

1.1 Introduction______________________________________________________________________6

2 PI Sheets - General Facilities____________________________________________________7

2.1 PI Sheet - Use_____________________________________________________________________7

2.2 PI Sheet - Header__________________________________________________________________8

2.3 PI Sheet – General Structure________________________________________________________9

2.4 PI Sheet – Calling Transactions______________________________________________________9

2.5 PI Sheet - Data Entry______________________________________________________________10

2.6 PI Sheet – Data Entry Validation____________________________________________________10

2.7 PI Sheet – Data Entry Copy details from SAP_________________________________________112.7.1 Copy details – Batch Split_______________________________________________________________112.7.2 Cut & Paste – Batch Details_____________________________________________________________12

2.8 PI Sheet - Integrated Batch Management_____________________________________________12

2.9 PI Sheet – Writing Data back into the PI Sheet________________________________________13

2.10 PI Sheet - Reporting Data________________________________________________________13

2.11 PI Sheet - Signature_____________________________________________________________14

3 Master Data & Configuration Objects____________________________________________15

3.1 Master Data Structure_____________________________________________________________153.1.1 Material Handling_____________________________________________________________________153.1.2 Master Recipes_______________________________________________________________________153.1.3 Material Allocation____________________________________________________________________163.1.4 Material Staging______________________________________________________________________173.1.5 BOM Master Data - Sort Strings__________________________________________________________173.1.6 Sort string - values_____________________________________________________________________18

4 PI Sheets & Control Recipes____________________________________________________19

4.1 PI Sheets & Control Recipes________________________________________________________19

4.2 Control Recipe Monitor Transaction CO53___________________________________________20

4.3 PI Sheet - Control Recipe Destinations_______________________________________________20

4.4 PI Sheet - Transaction Execution Modes______________________________________________214.4.1 Direct call of SAP transactions.___________________________________________________________214.4.2 Indirect call of SAP transactions__________________________________________________________21

5 Process Message Management__________________________________________________22

5.1 Process Messages Monitor_________________________________________________________22

5.2 Process Messages_________________________________________________________________23

6 PI SHEETS – Material Receipts________________________________________________24

6.1.1 CRD G1: PI Sheet Receipt (Preferred)_____________________________________________________246.1.2 CRD G2: PI Sheet Receipt (Optional)______________________________________________________256.1.3 CRD G3: PI Sheet Receipt (Mandatory for SU Materials)______________________________________256.1.4 CRD G4: PI Sheet Receipt (Preferred for non Batch materials)__________________________________276.1.5 CRD G5: No Goods Receipt on the PI Sheet________________________________________________27

7 PI SHEETS – Material Consumption____________________________________________28

7.1 Sort String = blank – default PI Sheet Materials_______________________________________287.1.1 Back-flushed Components_______________________________________________________________287.1.2 Non Batch Managed Materials___________________________________________________________287.1.3 Cancel Goods Movement_______________________________________________________________28

7.2 Sort String = 1 – By Product Materials_______________________________________________29

7.3 Sort String = 2 – Materials not on the PI sheet_________________________________________29

7.4 Sort String = 3 – Materials Storage Unit Managed_____________________________________30

7.5 Sort String = 4 – Consignment Stock_________________________________________________31

1 Material Handling Options for Production

1.1 Introduction

The functionality provided by EARTH Template V1 for material handling are basically divided into two different packages, each with significantly different functionality. The factory will have to decide which one of the packages to use for material supply and receipts from production.

The criteria for selection of the package will depend upon how the factory wishes to make use of batch management and storage unit management for traceability and control of materials in production. Each function brings with it a level of business benefit, master data complexity. The factory must decide:

1) Where, when, and how materials will be moved, consumed or produced.

2) The level of recording online in SAP or off line through a combination of operational and 'back office' procedures

3) The level of detail required for batch management and traceability, by pallet, material and quantity.

4) What other systems that are already in place will need to be retained, replaced by SAP or modified to support the EARTH template implementation.

The EARTH template is scaleable and each package will be more or less appropriate for a given business requirement.

The first package enables the factory to make use of bar code scanning keyboard data entry functionality for material consumption through a custom EARTH materials handling developed SAP front-end screens that can either be accessed through a SAP transaction code, or through a transaction call from the PI-sheet. This option requires the components to be staged to a storage type that has storage unit management active.

The second package is basically using standard SAP transactions and manual keyboard data entry for material consumption and receipts using a PI sheet. Postings can either be manually triggered from the PI-sheet that indirectly sends process messages to SAP or directly through normal SAP transactions like MB1A or by triggering a 'back-flush' consumption posting triggered by a process order confirmation.

Each package is mutually exclusive by material in that once configured and selected it will determine the options available and methods that MUST be adopted for materials issues, receipts and production confirmation. If the bar code scanning and storage unit management option is selected the SAP custom front end screens must be used for goods issue as the configured business processes block the use of SAP for goods issue using the transactions used for non storage unit managed materials.

PI Sheets have been developed that support both packages and are automatically generated according to the Master data that has been setup for the selected materials handling option on a material component basis. If the master data is not set-up correctly for the materials, factories may find it impossible to undertake the correct SAP transactions or generate PI Sheets.

2 PI Sheets - General Facilities

2.1 PI Sheet - Use

The Process Instruction Sheet, PI Sheet, enables an operator to undertake a limited set of transactions needed for the issue and receipt of materials and the creation/change of batch against a process order as their work activity takes place on a production line. The PI sheet enables a record of all operator activities to be recorded in a process message log, if the PI sheet triggered transactions are used.

The PI Sheet resembles a paper log that an operator would create as part of their work activity but additionally enables a user to undertake the business transactions as part of their daily production recording activities.

Operator can use the sheet as part of their production recording duties and at the same time report the information directly into SAP.

The Find PI Sheet transaction, CO60, allows the operator to call up a list of Process Instruction Sheets according to their set of selection criteria, making it easy for an operator to find the required PI sheet according to their individual needs, e.g. by order number, resource (usually line), material, date or control recipe destination etc. Most operators will use the control recipe destination as a search criteria for PI sheets.

The transaction returns a list of PI sheets that can be maintained or acted upon using the menu items.

PI Sheets can be printed to enable paper recording when computer equipment is not available. The PI sheet lists can be exported to Excel spreadsheets or E-Mailed from planning to production operations. They offer a replacement for paperwork systems without the overheads of using native SAP transactions but can be limited in their functionality for more complex recording and control scenarios. The EARTH template supports a scaleable solution in this area for 'on line' production recording.

2.2 PI Sheet - Header

The PI Sheet header is common for all the generated PI sheets and includes the information an operator may need to know about the material being produced.

For example, as shown in the above diagram by opening or closing the header window. It should be noted that the information displayed is in the order units of measure. The default settings for the order UOM is the material master production units of measure for the material. The order quantity decimalization settings e.g. Comma or dot notation can be different from the USER profile settings if the user has changed them.

2.3 PI Sheet – General Structure

The master recipe for this material had two control recipe destinations defined, G1 and G2. The control recipe destination G1: was used for two operations, 100 and 200, each with two phases 110/120 and 210/220, hence four sections are shown. The process instructions generated are combined for the same control recipe destination.

Phase Label Information

Open Window

Closed Window

2.4 PI Sheet – Calling Transactions

The PI Sheets offer push buttons to enable jumps to transaction screens where data is passed from the selected operation and phase. This enables the PI Sheet to limit the data entry required by the operator to only that which is required for the operational task. This simplifies the task of data entry for the operator and controls what may be done in transactions undertaken using this linkage mechanism.

For example, all milestone operations will require a confirmation by the operator for production activities, e.g. running hours, labor hours and materials that will consequently trigger any back-flush goods issues required.

2.5 PI Sheet - Data Entry

Data Entry is made into the PI Sheet in tables, where each line is used to record the data for a single SAP transaction. Data from one table line can be copied to another table line to reduce data entry and errors. The diagram below illustrates an example.

Phase long text

Time Ticket Confirmation TransactionCall Button

A checkboxis marked for the datato be sent

Icon deactivatesthe line if dataare not to be

sent

Scroll bar for customized

number of table lines

Values from one table fieldcan be used to default intoanother table field, even

within a different table

The red star marks the mandatory

fields

The cumulative quantity canbe calculated for the whole table and validated against

target quantity

Transaction datemay be differentfrom the actual

date

2.6 PI Sheet – Data Entry Validation

Data entry validation of the PI sheet table lines prior to initiating SAP transactions can be set up as part of customizing. This will help prevent errors prior to the execution of the SAP transaction. Any deviations can be noted by the operator and signed through their personal logon. Note this need not be the same as the logon used to open the PI Sheet.

2.7 PI Sheet – Data Entry Copy details from SAP

Two methods of copying details exist for the PI Sheet

2.7.1 Copy details – Batch Split

In this method a user can right mouse click on the batch number field to display a sub menu, 'Find Batch' that enable the selected batch and quantities to be automatically inserted into the PI Sheet. This is very useful where the quantity required is split across two batches and will result in two table lines being created. This method is available for WM non storage unit managed materials that do not create transfer requirements from the order reservation, e.g. Manually staged staging indicator value 4.

The usage quantity now is higherthan the tolerance for the target

quantity:- the deviation is recorded- the wrong value can be rejected- A warning Flag is indicated- if approved, a signature is

required

Signature strategies can be customized

for the password check

The diagram illustrates the automated entry of three table entries and update of the last batch selected into the Cancel Goods movement field.

The required quantity can be split across the batches available and Table lines will be automatically created. Strategies are set for picking the batch and how many splits are allowed.

2.7.2 Cut & Paste – Batch Details

In this method the user can call a SAP R/3 transaction or report, select the data they wish to copy and then cut/paste it back into the table line. Use control 'Y' to mark the field, Control 'C' to copy the data and Control 'V' to paste it into the PI Sheet.

2.8 PI Sheet - Integrated Batch Management

The PI Sheet supports the automated batch number generation and validation according to material type. This enables operators to create an initial batch or change batch on a pallet by pallet basis. The call batch number function calls a batch number based on the EARTH format. Dependent on the configuration settings a changed value not according to the EARTH format can

A button can be used to call another transaction

to view additional data to execute other steps

The find batch menu is selected by right mouse clicking this field

be accepted with a signature or is forced to get rejected so that only values according to the format are to be sent by the operator.

2.9 PI Sheet – Writing Data back into the PI Sheet

The EARTH custom transactions for issuing and receiving storage unit managed materials report transactions back into the PI Sheet so that a complete history of operator activity is recorded.

A new batch number is created according to plant-specific rules

This value was rejected:the line is now greyed out

The production datemay be different fromthe actual date

Confirmed batch record data are nowreported:- a new batch record is created- the value is sent to the process order- the batch record also contains the production date

The default batch numbermay be changed or extended,it then is validated accordingto the plant-specific rules

The batch number defaultsautomatically into the nextinstruction for goods receipt

2.10PI Sheet - Reporting Data

Each table line has an icon to deactivate the line from being reported and is automatically removed after the line has been reported. The cumulative quantity button can be selected for the total issued quantity to be displayed.

2.11PI Sheet - Signature

Before an order can be technically completed all the open PI Sheets must be completed. Before the PI Sheet can be completed it must be signed by an authorized user. Comments can be made at this point and the PI Sheet completed.

The signature process at the end of the PI Sheet automatically triggers the completion of the PI sheet. Before entering the final signature step, all prior process instructions must either be completed or deactivated (no table lines must be open).

3 Master Data & Configuration Objects

3.1 Master Data Structure

3.1.1 Material Handling

More detailed information on the master data for materials handling for consumption can be found in the guideline GT_Guideline_Matconsumption_manufacturing.doc. This guideline will focus on how to set-up the PI Sheet Master data needed for the various options of storage unit and non storage unit material management.

For each process order raised the material components will be staged according to the predefined master data setup. The diagram illustrates the extent to which the different master data objects interact with WM material staging and the master recipe used to generate the PI sheet.

3.1.2 Master Recipes

The PI Sheet is generated from the process instructions contained in the control recipe of the process order. The master recipe defines the resources, operations and phases required to make the product. These are linked through the SAP master data and the EARTH template configuration to generate the correct PI Sheet for consumption and receipt.

Master RecipeOperations Resource Supply area

Phases BOM Materials Storage Type/BinCRD

Process Instructions PI Sheet

Process Order

110

Phase

X Y Z

BOM

Recipe ResourceProduction Supply Area

Control CycleRecordMat.X/Plant/PSA

Control CycleRecordGenericPlant/PSA

Control CycleRecordMat.Z/Plant/PSA

Storage Type140

Storage Type145

Storage Type140

Resource

StorageBIN

StorageBIN

StorageBIN

Control Cycle Record

SU Management level

Reference a References a

have an allocated are sourcedfrom a

Have a set ofare used togenerate a

Storage types

145: SU Managed140: not SU Managed141: not SU Managed

The following diagram illustrates a typical Master recipe that comprises three resources, three operations each with one or more phases.

In this case two PI Sheets will be generated, one for each destination. The G1: PI Sheet will contain all the process instructions required for the material consumptions, milestone confirmations and any by product or co-product receipts needed in the operations 100 and 200.

The G2: PI Sheet will contain all the process instructions required for operation 300 that will also include a signature instruction. It is important to remember that:

A process order will NOT be able to be technically completed before all sections of the PI Sheet have been completed.

The control recipe destinations must be selected with a knowledge of the material handling requirements of the produced or consumed material and the 'sort string' master data set-up appropriately in the material BOM.

The method of receipts and consumption must be appropriate for the physical operation and availability of information.

3.1.3 Material Allocation

Material allocation to the correct phase is important and can be seen in the diagram below, one material - 10000146 is allocated at phase 120 and the others at phase 320. Phase 120 has a resource MILKRECP.

Materials 10000061, 63 & 64 are SAP bulk materials that will not appear on the PI Sheet (no reservation item will be created). It is important to ensure that the material is allocated at the correct phase/resource and its BOM sort string is correct, otherwise it may not be possible to issue the material from the PI Sheet.

3.1.4 Material Staging

The resource supply area must have a default control cycle record that defines a storage type and bin for the production supply area before a material can be issued. The configuration of the storage type also defines if the bin is to be storage unit managed or not. This information then enables the correct selection of Control Recipe Destination, and hence PI-Sheet to be made.

The control cycle record for material 10000146 in the supply area MILKRECP identifies a storage type 141 and storage bin FAT-SNF for the source of material needed by phase 120.

Storage type 141 is non storage unit managed and manually staged, (indicator =4) and hence can be issued directly from the PI Sheet.

A default control cycle record can be configured by plant and supply area for all materials with a 'pick part' staging indicator =1.

In this case it is important to ensure that ALL materials allocated to phases on the PI sheet comply with the default storage type and their master data sort strings have been set up correctly, i.e. value =3

All materials must have a control cycle record unless staged using 'pick part' strategy. If materials are sourced from an alternative supply area to the default, they will need a specific control cycle record defining for each material. All materials that are staged to a supply area with storage unit management configured storage type, e.g. 145, will need to use the EARTH custom material handling development 'front-end' for goods issue and receipt.

3.1.5 BOM Master Data - Sort Strings

For each resource/material component master data must be maintained on the BOM to control the correct generation of process instructions that will be needed on the PI sheet for the material consumption, receipt and order confirmations. The 'Sort string' field on the BOM holds a value that is used by the SAP configuration process for generating the correct combination of process instructions needed on the PI Sheet. The Table line fields required for material issues, receipts and confirmations are automatically generated according to the value of the sort string.

Each operation is undertaken by a resource in one or more phases. Materials that are defined on the BOM are allocated to one or more phases. Each phase must be associated to a single control recipe destination. The sort strings for the material on the BOM are used to generate the process instructions needed and has a major influence on where, when and how the material consumption posting will be done in the PI Sheet environment. The diagram below illustrates the key master data objects to be maintained for the generation of the control recipe and PI Sheet. The sort string field on the BOM holds the EARTH custom master data that is used to generate the PI Sheet variants for Goods issue.

3.1.6 Sort string - values

The sort string does not influence where and how the components will be staged but it has a major impact on the preferred process for where, when and how the material consumption posting will be done in a PI-sheet environment. The current configuration in place for sort string functionality looks as follow.

Sort string 1 = To identify by-products within the PI-sheet.

Sort string 2 = To filter out components not to be issued from PI-sheet (process messages).

Sort string 3 = To identify components to be issued from front end for scanning.

Sort string 4 = To be used for components to be issued from vendor consignment stock.

Sort String 5 = To filter out components not to be received on the PI Sheet

Material 10000146 has a blank sort string value, it is not back flushed and not batch managed. We are now able to look at how the various combinations of this master data can be used to configure PI Sheets for a variety of production operations.

Its worth making the point here that the EARTH PI Sheet solution can be used in a variety of circumstances found in production operations, provided the master data is correct and maintained.

4 PI Sheets & Control Recipes

4.1 PI Sheets & Control Recipes

The Control Recipe and PI sheet are separate objects as far as SAP is concerned, each with their own status and monitor. It is important to understand these relationships so that recovery from errors in operational transactions or master data can be corrected.

It is important to remember that:

The PI Sheet is an object generated from the control recipe and is dependent upon the control recipe destination.

The Control recipe is automatically generated according to the EARTH template settings that are NOT changeable.

The changes to the process order will not be reflected in the control recipe after it has been generated.

The control recipe monitor is a technical interface as far as plant operation is concerned and should not normally be needed for the destinations G1, G2, G3 G4 or G5. The control recipe monitor is only needed for external interfaces and manually discarding a control recipe once a PI sheet has an 'in-process' status.

Process Order

EARTHTEMPLATE

Configuration

BOMMaster Data

Sort StringsValues = 1, 2,3 or4

Master Recipe

Control Recipe Destination =G1, G2, G3, G4 or G5

Control Recipe

PI Sheet

Control Recipe Monitor

Transaction CO53Automatically GeneratedProcess Instructions

PI Sheet

Transaction CO60

4.2 Control Recipe Monitor Transaction CO53

The control recipe monitor transaction enable control recipes to be viewed according to selection criteria, e.g. Order number, control recipe destination, date etc.The monitors then display all the control recipes that meet the selection criteria. In the example,

two control recipes have been generated one for destination G1 and another for destination G3. It can be seen that one destination will be used for PI sheet Goods issue of non storage unit managed materials and the other for palletized materials.

4.3 PI Sheet - Control Recipe Destinations

Five generic PI Sheets have been configured that will be automatically generated according to the control recipe destination selected in the master recipe, G1, G2, G3, G4 & G5. The type of material receipt being used in production defines the destination that must be used. The options available are as shown in the table below.

Control Recipe Destinations for PI Sheet Goods Receipt

G1: G2: G3: G4: G5

Batch Managed & non SU Managed

X

Preferred

X

Optional

Non Batch Managed & Non SU Managed

X

Optional

X

Preferred

Batch Managed &SU Managed

X

Mandatory

Non Batch Managed &SU Managed

X

PI Sheet not used for

Goods Receipt

4.4 PI Sheet - Transaction Execution Modes

The PI sheet provides an environment for the process operator that enable them to carry out all the transactions needed to execute a process order. The transactions needed will vary according to the business scenario adopted for materials handling. It is important to remember that the PI Sheet has two modes of transaction operation:

4.4.1 Direct call of SAP transactions

In this case the operator will be required to respond to any error messages that may occur and may also have to wait if other users are accessing SAP that block duplicate operation. This mode of operation is necessary where the complexity of the task needs to be undertaken directly in SAP and has not been delegated to the indirect call of a SAP transaction.

This mode is used for the following functions:

Process Order Confirmation Storage Unit Managed Material Receipts and Issues Access to SAP Reports

It can also be used for non storage unit managed material receipts using the MB31 SAP transaction.

4.4.2 Indirect call of SAP transactions

In this case the operator can use the PI sheet to enter data that is validated and checked for appropriateness before a process message is sent to initiate a SAP transaction. This mode of operation enables the operator to work without having to wait for the SAP transaction to execute. This has some advantages of allowing operators to enter data into the system in advance of its transaction processing. It also has a disadvantage that any errors of content are only reported back to the operator at the point of data entry if a validation is configured for the field.

This mode of operation is used for the following functions:

Issues and receipts of Non Storage Unit Managed materials Creation of a new material batch record Signature and completion of the PI Sheet

5 Process Message Management

Process message management is a key requirement for factories to check that all messages have been correctly processed and any failures are investigated and re-sent. The SAP process message monitor is used for this purpose.

5.1 Process Messages Monitor

Factories will need to establish procedures for checking that all the process messages generated by the PI Sheet have been successfully processed by SAP. Although most detectable errors are validated during data entry there are circumstances when they can fail and that will need some corrective action. For example, if an operator is consuming material using process measurements that consume more material than is available in the supply area. The Process message monitor, CO54 is the tool used for checking and resolving any message failures.

Process messages that are sent from the PI Sheet can be displayed using the Process message monitor transaction. Facilities exist for displaying or editing the data sent from the PI Sheet when a failure (destination error) occurs. These may be due to a number of reasons usually:

1) Deficit of Stock for a goods issue

2) Incorrectly generated PI Sheet for the BOM settings, i.e. using a non-storage unit managed PI sheet setting for a storage unit managed material.

5.2 Process Messages

Y_CONS Used for reporting the consumption reporting of non batch managed material Y_CONS_B Used for reporting the consumption of batch managed material Y_CONS_R Used for consumption of By Products Y_CONS_S Used for Consignment stock Goods issues Y_CONS_C Used for Consumption Cancellations

Y_BATCH Used for creating a new batch record and updating the order details Y_PROD Used for reporting the production of non batch managed material Y_PROD_B Used for reporting the production of batch managed material SIGN Used for completing the PI Sheet. PI_CRST Used for changing the status of the control recipe and related PI Sheet

These messages are processed by the PI sheet automatically using the 'report data' right mouse 'button menu'. There is no requirement in normal circumstances to manually create process messages, but if it is necessary then the process message transaction, CO57 is the tool that is needed to manually create messages.

It is not necessary to execute these steps manually as SAP background jobs are set up for:

sending the control recipe

sending the process messages

This tool may need to be used to change the status of a PI Sheet that has a status 'in progress' and needs to be discarded and a new one created because of incorrect master data. The standard SAP process does not allow the discard of a PI Sheet once it has a status 'in process'. However. if this should happen then the following 'non SAP recommended' procedure can be used. Do NOT discard the PI sheet using the discard/delete menu option of CO60. The correct procedure is:

1) Create and send a process message to discard the control recipe using CO57.

2) Use the find PI Sheet transaction CO60 menu item to discard the PI Sheet.

3) Change the process order COR2 menu path and delete generated process instructions.

4) Correct the Master data that is in error on the order, and later the Master recipe

5) Re-Generate a new control recipe and PI Sheet, the new one will NOT show the previously entered information.

6 PI SHEETS – Material Receipts

6.1.1 CRD G1: PI Sheet Receipt (Preferred)

G1 is the normal control recipe destination for receipting materials that are batch managed and not storage unit managed. The call batch number function will generate a batch number which when validated will populate the table line for goods receipt and send a process message, Y_BATCH.

This process message triggers two tasks:

1) Create the batch master record and update the production date. The product availability date in the batch master record is also updated based on material master settings.

2) Update the process order goods receipt batch, this is used to recall the current batch for receipt

If the PI Sheet is not used, then these additional tasks will have to be performed manually using standard SAP transactions.

After a batch has been generated a production receipt can be made. In this case the material 1000015 is a finished material and the batch number is appropriately generated and used for the process message for receipt, Y_PROD_B

PI Sheet G1 is used for most production operations not involving pallets, e.g. Silos, Tanks and vessels that are not storage unit managed. It should be noted that the operator will not receive any direct feedback from this activity regarding message failures and should be aware that any errors will need later correction.

The Goods receipt is an indirect mode of operation.

Phase Info Text

Phase Info Text

6.1.2 CRD G2: PI Sheet Receipt (Optional)

For example, materials that are not batch managed and not storage unit managed materials have two options available for receiving, G2 and G4. If control recipe destination G2 is used then a direct function call to the SAP MB31 transaction is required for Goods receipt.

This means that the displayed PI Sheet for G2 will have a push button displayed to call the MB31 transaction.

PI Sheet G2 is used in those cases where factories prefer to undertake transactions using direct transactions in SAP. This has the merit of providing immediate feedback to the operator in the case of error. There is no relative merit in using this approach over recording results directly in the PI Sheet.

The Goods receipt is a direct mode of operation.

6.1.3 CRD G3: PI Sheet Receipt (Mandatory for SU Materials)

Material Receipts for Storage Unit managed materials can only be undertaken using a EARTH custom development. In this case a push button is included to call the Material handling Custom front end transaction. The call batch button is used to propose a batch number in compliance with the EARTH requirements, i.e. Julian Date XXXX, Plant XXXX leaving two blank characters XX for user entry, e.g. TJ. The production date is defaulted to the current date, but can be changed by the operator.

The report data function sends a Y_BATCH process message that calls custom EARTH functions to create the batch master record, in this case 207Z203TJ with a production date, in this case 14.03.2002 and records the batch number, 207Z203TJ on the production order header for Goods receipt. Mandatory fields are show with a red '*'.

The data entered MUST be checked 'OK'.

A right mouse menu must be used to report the

data BEFORE a goods receipt can take place. When this has been done the 'deactivate' icon is removed.

In this case the batch number is NOT written into the goods receipt Table Line as this is done by the custom materials handling transaction AFTER goods receipt and pallet label printing.

When the call WM function for GR button is pressed data is passed from the PI sheet to the materials handling front end. This also automatically fills in the data from the production order header for the batch and from the batch master record the production date. All the operator is required to do is fill in the quantity to be produced and press create when a pallet label will be printed.

This use of G3 PI Sheet is mandatory for receiving and issuing storage unit managed materials.

The call WM function for GR push button calls a custom EARTH transaction that MUST be used as the standard SAP transactions do not allow the issue of materials to a process order from a SU managed bin. This function can be found in the materials handling guideline, GT_Guideline_Matconsumption_manufacturing.doc

The Goods receipt is a direct mode of operation.

6.1.4 CRD G4: PI Sheet Receipt (Preferred for non Batch materials)

If control recipe destination G4 is used there is no batch field available on the PI Sheet and a process message is sent for goods receipt.

Machine/Labor confirmations are linked to the signature and receipt operation so you can also see a push button has been generated for this purpose.

The Goods receipt is an indirect mode of operation using a Y _PROD process message.

6.1.5 CRD G5: No Goods Receipt on the PI Sheet

This CRD G5 allows the receipt product to be from the PI Sheet, for example, if SAP transactions or the Materials Handling front end development for Storage Unit Managed materials is going to be used. A confirmation is requirement is still generated.

NOTE: In other respects it is identical to G3.

7 PI SHEETS – Material Consumption

7.1 Sort String = blank – default PI Sheet Materials

7.1.1 Back-flushed Components

Back flushed components are shown on the PI sheet for information purposes. No data entry fields are generated.

7.1.2 Non Batch Managed Materials

For materials that will be consumed on the PI sheet the implication is that the materials cannot be sourced from a supply area that is storage unit managed.

Material 10000146 is not batch managed and has a blank sort string. In this case the process instruction used to generate the table line does not include a mandatory batch field and the process message Y_CONS will be generated.

7.1.3 Cancel Goods Movement

The Cancel goods movement will generate a Y_CONS_C process message. The batch field is non mandatory and will be copied from the consumption line into the cancel goods movement.

In this example material 10000147 is batch managed and the process instruction generates a batch field for consumption and will generate a Y_CONS_B process message. The cancel Goods movements is unchanged Y_CONS_C, as is the LS 26, WM storage information report call.

7.2 Sort String = 1 – By Product Materials

This is used for consumption of materials that are by products.

Material 1000093 has a sort string = 1 and will generate a Y_CONS_R process message for by Product consumption

7.3 Sort String = 2 – Materials not on the PI sheet

These materials will not appear on the PI Sheet

7.4 Sort String = 3 – Materials Storage Unit Managed

When a sort string of 3 is used the PI Sheet is generated with a button to call the material handling front end. The Goods issue batch is written back into the PI Sheet detail after the Goods issue transaction has been completed and the user returns to the PI sheet.

Goods issue reversals can only be made by using the reverse button in the Material handling front end.

7.5 Sort String = 4 – Consignment Stock

This is used for materials that are consignment stock and NON SU managed. In this example the process instructions generate additional fields of vendor and stock type indicator. In the case that materials are held as consignment and also non consignment the operator must indicate this by checking the stock indicator prior to the Y_CONS_S process message being sent.

If SU managed consignment stock will be consumed then sort string 3 should be used.

8 PI Sheet Construction

8.1 Process Instructions

The PI Sheet is generated from process instructions in the control recipe. The process instructions in the control recipe are generated by the SAP configuration of the EARTH GT1 template. The process instructions form the building blocks of the PI sheet and determine its functionality and appearance.

INSTR Category PI Sheet Variant

Purpose

Y_HTML_N All HTML style sheet new design

Y_HEAD_I All PO Header Information, new HTML

Y_SIGN All Request a signature

YGTQM All Inspection Results Recording

Y_CHARGEY G1 Batch number for product, checks

Y_GR_H3 G1 Goods receipt IM, batch creation, HTML

Y_MB31 G2 Goods receipt for products with MB31

Y_GR_H2 G4 Goods receipt in IM, no batches, HTML

Y_LS26 All All materials except by-products & materials not on the PI sheet - Materials informations, LS26

Y_BACKFL All All materials except by-products & materials not on the PI sheet

Information for backflushed comp, HTML

Y_GI_IHB All Goods issue of batches in IM, HTML

Y_GI_IHK All Goods issue of consignment batches

Y_GI_IHC All Cancel Goods Issue request, HTML

Y_IB_H1 All Goods receipt in IM, batches, HTML

Y_GR_IRH All Goods receipt byproducts, batches, HTML

Y_GI_IH All Goods issue of components in IM, HTML

Y_CF_MST All Phase confirmation for milestones

Y_CF_MCH All Phase confirmation for machines

Y_CF_LBR All Phase confirmation for labor

Each process instruction is automatically generated and determined by filters that have been set-up in GT1 configuration. For example, the process instruction may configure table lines with requests for data and provide a field for input, push buttons for function calls etc.