SAP PP Production Model

8/9/2019 SAP PP Production Model

http://slidepdf.com/reader/full/sap-pp-production-model 1/10

BOM, Master Recipe, Production Planning & Batch ManagementProcesses

• BOM and Master Recipe will be created for finished goods and at each intermediate

inventoried / stockable level• Manufacturing plant receives demand for Finished goods from customers or forecast

• MRP creates planned orders for production. Planned orders will be scheduled and a firm

plan is generated for a week ! "a# Rolling$.

• Planned orders are converted into process orders for e%ecution

• Batch numbers are created in &'P for raw materials( semi)finished materials and

Finished *oods.

• Finished goods are received into warehouse and shipped to customers / distribution

centers / other plants



Production Model in SAP – Option 1( Stolberg)

Mi%ing &pra# "r# Packaging

Process Order +, semi)finished$

&emi Finished *oods

BOM - Material Recipe

Finished

*oods"emand

MRP

Manufacturing

Plant$

Planned Order for Manufacturing

Production &cheduling

and Firm Plan

endor PurchasingPurchaseOrders

Receive

Material(

'ssign Batch Vendor Batch

Number (

Expiration

Date$

Material &taging

for Production

&hipping

Finished*oods

Batch

Process Order +

Finished *oods

BOM - Material

Recipe

Finished*oods

Batch

BGS-00001 (ST-SP/555-110)

BGS-00001-0001 (ST-SP/555-110)

Pro , &MF 0 1111

Pro F* 0 ,1111 Bags$

Pro 2 F* 0 ,1111 &uper &ack$

Pro ,

Pro

Pro 2

3%ample



Production Model in SAP – Option 1 ( Stolberg)

PRO

Standard Production model Used EU & North America

SAP Best Practice, when Semi finishedmaterials is used to fulfill multiple packagingtpes !Bags etc"

#ustomi$ed Recipe Authoring tool %uilt arecipe at Semi fished e'el

SAP planning at Semi finished le'el andconsume Semi finished plan with customerOrder

#ON

Stol%erg manufacturing is a continuous process, with no in'entoried semi fishedmaterial !(oes Not reflect at actual production

process"

Semi finished )aterial is traditionall createdwhen a material is in'entories and issues to

multiple Pack Process Order

#reate a additional process order for Semifinished

Same Batch Num%er is created for )ultiple(ifferent )aterials !Bad manufacturingPractice"

E*tra confirmation and closing of Processorder

Semi finished )aterial is a 'irtual material



Production Model in SAP – Option 2( AS – S Br!"il)

Mi%ing &pra# "r# Packaging

Process Order +, Finished *oods$

Finished

*oods

"emand

MRP

Manufacturing

Plant$

Planned Order for Manufacturing

Production &cheduling

and Firm Plan

endor PurchasingPurchase

Orders

Receive

Material(

'ssign Batch

Vendor Batch

Number (

Expiration

Date$

Material &taging

for Production

&hipping

Finished

*oods

Batch

Finished *oods

BOM - Material Recipe

BGS-00001-0001 (ST-SP/555-110)

Pro F* 0 ,1111 Bags$Pro ,

3%ample



Production Model in SAP – Option 2 ( AS – S Br!"il)

PRO

AS+ S Process in Bra$il

SAP Best Practice in continuousmanufacturing en'ironment

One Process Order Per run !one - to - one "relationship

SAP planning at finished material le'el andconsume plan with .inished goods customerOrder

)aster Recipe is maintained at .inishedgoods le'el

Batch Num%ering is standard SAP Best

Practice

#ON

Process is not harmoni$ed with other regions

Recipe Authoring tool

#reate a additional process order for Semifinished

Same Batch Num%er is created for / different)aterials



#or$%&op Scope' Production ecution / S&op *loorecution

• Production Planning 4andoff to Production 3%ecution

• Process Order Release

• Read the Master Recipe / Production ersion

• 5reate a Batch 6umber

• Print &hop Floor Paper

• 5omponent 7ssues to Process order with 'utomatic batch selection F7FO• Production 5onfirmation / *oods Receipt

• Production 8ualit# and Batch 5haracteristics

• 7n)Process Re)work vs. &tock Re)9ork

• 5O*7 Processing

• :ogistical completion of Production Orders



Production Order Execution Steps

5reate

Process

order

5omponent

'vailabilit#

check

Read Master

RecipeRelease

Process

order

'ssign Batch

6umber Print &hop

Floor Papers

Material

erification

Post goods

issue with

'utomatic

Batch

"eterminatio

n

Production

5onfirmation

5O*7

Processing

;echnicall#

complete

production

order

&ettle

production

order costs

8ualit# ;ests(

batch

derivation

Put awa# the

material

produced

Pack and

print labels

Post goods

receipt



Production +u!lit, !nd B!tc& &!r!cteri%tic%M!nu.!cturing !lue

Stre!

RawMaterial

Receiving

8ualit#7nspectio

n

Mi%ing &pra# Packaging

7ncoming

;ruck

7nspection

Considerations:

'll trucks have

7ncoming ;ruck

7nspections and will

all be entered

directl# into &'P.5ould <ust be a

check bo% and

7ncoming 7nspection

sheet could be

scanned in.

7nspection

:ot

=sage

"ecision

7nspection

:ot7nspection

:ot

Key Decision: =sage "ecision



OG Proce%%ing(Ontroling Good% %%ue%)

• COGI is a reprocessing log or

!oth GI"s and GR"s that ha#e

errored$

• Pro#ides a means to allo%

manuacturing #alue chain to

continue %ithout dri#ing

in#entories negati#e$

• Correct Master ata ' Batch

ata is essential$

• Extremel( important to

address COGI errors and

resol#e )S)P$

• e, eci%ion' COGI errors to

!e resol#ed during and !( the

completion o each shit * B(

+B Role$ C)-GE

M)-)GEME-+..



APP34

#&!t i% ! P) P is a short orm or /Process e0nition ocument1$ )ll the re2uirements o a gi#en

process are gathered, re#ie%ed and appro#ed in a MS %ord document, %hichoriginates rom an appro#ed template

#&!t i% ! P*6) P34 is a short orm or /Process 3lo% diagram1$ +his is t(picall( a s%im lane diagram

5%hich is em!edded into the P346 %hich descri!es )44 the steps to complete aprocess$

#&!t i% ! *unction!l %peci7c!tion) 3unctional speci0cation is a document that descri!es the unctionalit( o the desired

!usiness re2uirements, speci0c to a !usiness %hen standard S)P does not addressthis$ +his is created onl( or appro#ed gaps 57 appro#ed gap 8 7 or more unctionalspec$6

#&!t i% ! G!p) gap is documented %hen the S)P standard unctionalit( does not address a !usiness

re2uirement$ +he Gap is documented and presented to PMO or appro#al$ Iappro#ed, the Gap is closed usuall( !( %riting unctional speci0cations to de#elopthe re2uired unctionalit(

#&!t i% # – 8 – – – – *

9 * 9or:;o%, R * Report, I * Interace, C * Con#ersion, E * Enhancement,

Documents

SAP PP Production Model