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Production Planning
Work Centers for Fitter SnackerR
aw M
ater
ial W
areh
ouse
(10
0) Mixer
Mixer
Mixer
Mixer
Form Bake Pack
Fin
ishe
d G
oods
War
ehou
se (
300)
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
2
Order Creation
3
AvailabilityChecks
MachineReservation
4
Order Release5
6
Print Order7
Download toPDC system
8
Material staging9
Material withdrawalposting
10
Upload 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
Ma
teria
l
Material
OP0010
OP0020
OP0030
OP0080
OP0090
……..
Material
Ma
teria
l
Assigned via BOM: All materials assigned to first operation
Assigned via Routing: Materials can be assignedto specific operations