bp discrete manufacturing v1605 overview en be

SAP Best Practices for Discrete Manufacturing V1.605

SAP Best Practices

General Information

SAP Best Practices for Discrete Manufacturing was developed for small and midsize manufacturers to implement a solution quickly and easily.

By means of an entry-level offering for manufacturing companies, you gain built-in support for the best business practices in the industry.

Functionalities

The SAP Best Practices for Discrete Manufacturing V1.605 solution supports your business in the following areas :

Materials management

Production planning and control

Sales and distribution

Logistics, product life-cycle management, and quality management

Accounting

Controlling

Forms and reporting

SAP BP for Discrete Manufacturing V1.605Solution Scope (1 of 2)

Manufacturing Sales Materials Management Financial Accounting

Analytics

Make-to-Stock Production – Discrete Industry

Make-to-Order Production with Variant Configuration

Make-to-Order Production without Variant Configuration

Repetitive Manufacturing

Production Subcontracting (External Processing)

Rework Processing for Stock-Manufactured Material

Rework Processing for Work-in-Process

Quality Management (QM) in Discrete Manufacturing

Manufacturing with Kanban Supply in Production

Planning and Processing of Semifinished Goods

Co-Product Manufacturing

Tool Production

Engineer-to-Order (ETO) – Project Assembly

Make-to-Stock (MTS) Production with Order Split

Records Management

Lean Manufacturing: Heijunka Leveling

Sales Processing Using 3rd Party (w. Ship.Not.)

Credit Management

Sales Order Processing – Sale from Stock

Free of Charge Delivery

Returns and Complaints

Sales Quotation

Sales Order Processing for Prospect

Sales Processing using Third Party (without Shipping Notification)

Sales of Nonstock Item with Order Specific Procurement

Debit Memo Processing

Foreign Trade Export Processing

Customer Consignment Processing

Returnables Processing

Batch Recall

Lean Warehouse Management

Sales Order Processing with Customer Down Payment

Sales: Period End Closing Operations

Credit Memo Processing

Handling Unit Management (HUM) for Production Order

Sales with Scheduling Agreements

Engineer-to-Order (ETO) – Quotation Processing

Sales Returns with Quality Management (QM)

Advanced Customer Returns Management

Cash Sales Orders

Shipping and Receiving with WM

Batch Management

Serial Number Management

Quality Management for Procurement with Vendor Evaluation

Quotation for Procurement

Consumable Purchasing

Procurement without QM

Stock Handling: Scrap and Blocked Stock

Procurement Contract

Stock Transfer with Delivery

Stock Transfer without Delivery

Return to Vendor

Physical Inventory/ Inventory Count and Adjustment

Subcontracting

Procurement & Consumption of Consigned Inventory

Foreign Trade Import Processing

Purchasing with JIT Delivery Schedules

Advanced Batch Management

Outsourced Manufacturing

Third-Party Order Processing with Subcontracting

General Ledger

Accounts Receivable

Accounts Payable

Cash Management

Asset Accounting

Asset Acquisition through Direct Capitalization

Asset Acquisition for Constructed Assets (Investment Orders)

Activate Document Splitting

Cost of Sales Accounting

Segment Reporting

Internal Order R&D Actual

Overhead Cost Accounting – Actual

Period End Closing Financial Accounting

Period End Closing Projects

Internal Order for Marketing and Other Overhead Actual

Activate Document Splitting for Discrete Manufacturing

SAP ERP Reports for Accounting

SAP ERP Reports for Logistics

Controlling

Purchased Material Price Planning

General Cost Center Planning

Manufacturing Cost Center Planning

Internal Order R&D Planning

Internal Order for Marketing and Other Overhead Planning

Standard Cost Calculation

Research and Dev.

Internal Product Development

New ScenariosEnhanced Scenarios

Services

Spot Consulting with Fix Priced Billing

Internal Project

Internal Maintenance

Service with Time & Material Based Billing

Service with Fixed Price Billing

Procurement of Third-party Resources

External Procurement Services

Depot Repair

Period End Closing Service Orders

Maintenance and Warranty Processing

Easy Depot Repair

SAP BP for Discrete Manufacturing V1.605Solution Scope (2 of 2)

Cross Functions

Period End Closing Activities

Period End Closing “General” Plant

Inventory Valuation for Year End Closing

Time Recording

Travel Management

© SAP 2011 /

Industry-Specific Scenarios (1 of 3)

SAP Best Practices for Discrete Manufacturing V1.605 provides the following industry-specific scenarios:

226: Handling Unit Management (HUM) for Production Order

227: Quality Management in Discrete Manufacturing

229: Advanced Batch Management

230: Purchasing with JIT Delivery Schedules

231: Sales with Scheduling Agreements

232: Engineer-to-Order (ETO) – Quotation Processing

240: Engineer-to-Order (ETO) – Project Assembly

233: Manufacturing with KANBAN Supply into Production

234: Planning and Processing of Semifinished Goods

235: Co-Product Manufacturing


EhP 5EhP 5

© SAP 2011 /



236: Tool Production

237: Sales Returns with Quality Management (QM)

238: Cash Sales Order

239: Shipping and Receiving with Warehouse Management

248: Make-to-Stock Production with Order Split

249: Outsourced Manufacturing

250: Advanced Customer Returns Management

252: Third-Party Order Processing with Subcontracting

253: Lean Manufacturing: Heijunka Leveling

661: Records Management

EhP 5EhP 5


EhP 5EhP 5

© SAP 2011 /



245: Activate Document Splitting for Discrete Manufacturing

274: Maintenance and Warranty Processing

275: Easy Depot Repair


Purpose Handling Unit Management (HUM) is used to control logistical processes. A handling unit represents a physical object in the SAP system. It consists of a load carrier, one or

more packed products and an unlimited quantity of packaging materials. Each handling unit has a unique identification number, which is typically printed as a barcode on a material tag.

You can specify the material and the quantity that is to be packed in certain packaging, that is, in one handling unit. These requirements are reproduced in a packing instruction. This packing instruction can be used to create handling units automatically.

Benefits Automatic packaging according to packing instructions Track movements of groups of individual materials by tracking the handling units that contain them Full integration into the logistic chain The scenario offers you the possibility to demonstrate HUM with or without warehouse management

Key process flows covered Creation and release of production order for handling unit (HU) production HU packaging in production order Goods receipt for produced HU Monitoring of HU Confirming production of HU HU handling with WM or HU handling without WM

Purpose and Benefits:

Handling Unit Management (HUM) for Production (226)

Purpose This scenario deals with quality inspection activities during the production process.

Quality activities are required both when a product is manufactured in-house and when the production involves external processing where parts of the production process are done by a subcontractor.

Benefits Two sub-scenarios to cover both goods acceptance and goods rejection or acceptance and

rejection of the external processing respectively. Quality Notification to track quality issues, and trigger further actions, such as re-work or

scrapping

Key process flows covered QM for goods receipt of production order QM with In-process control QM for goods receipt of external processing Acceptance and rejection of goods/ external processing work are both covered


Quality Management in Discrete Manufacturing (227)

Purpose You get the complete batch history data including the evolution of a batch, by

considering all relevant batch-related object types (BRO types) maintained in different SAP and external systems.

Benefits To track the transactional data related to batches To find out where a batch was used, e.g. to perform a batch recall or for

evaluation purposes To find out where a batch is used, e.g. in which stocks or inspection lots or

material documents To have a single point of batch maintenance

Key process flows covered Batch information cockpit with Batch History


Advanced Batch Management (229)

Purpose This scenario focuses on JIT procurement. It describes an inbound process in a typical repetitive manufacturing environment.

Benefits Streamlined demand flow from customer to supplier High integration of customer’s and supplier’s supply chain managed by cumulative quantities Shorter process times Reduction of inventories to a minimum

Key process flows covered Create scheduling agreement for vendor material Update scheduling agreement with forecast and JIT delivery schedules Enable traceability via batch or serial number assignment Create Scheduling Agreement Release Print and Transmit Scheduling Agreement to vendor Goods receipt posting with reference to scheduling agreement Billing


Purchasing with JIT Delivery Schedules (230)

Purpose Scheduling agreements are widely used in Discrete Industries. This scenario focuses on a order-to-invoice cycle. It describes an outbound process in a typical series business environment.

Benefits Streamlined demand flow from customer to supplier High integration of customer’s and supplier’s supply chain managed by

cumulative quantities Shorter process times Print out forms support the basic requirements of discrete industries

Key process flows covered Create basic customer contract called scheduling agreement Update scheduling agreement with forecast and JIT delivery schedules Display item due for delivery and create outbound delivery for available parts Enable traceability via batch or serial number assignment WMS controlled picking; packaging according to customer‘s packing instruction Invoice items and transfer to accounting Receive self-billing information from customer


Sales with Scheduling Agreements (231)


Purpose This scenario describes the quotation processing in a standard Engineer-to-Order (ETO) environment.

SAP functionalities of Sales & Distribution (SD) and of Project System (PS) are used to control the

complete process, from customer inquiry to the handover to project assembly (described in the scenario 240, ETO Project Assembly).

In addition to the SAP reporting functionality also the special purchasing functionality “long lead time procurement” is part of the process.

Benefits Deep integration to the project structuring and calculation allows for a consistent controlling of all

steps and values Copy functionalities – e.g. from inquiry to quotation – are facilitating compliance with the process rules All values and parameters for the subsequent process (ETO 240) are available as default parameters The option for the creation of project versions are allowing a continuous recording of all relevant

values along the controlling process and a later comparison of the several situations The long lead time procurement process is an important step to guarantee material availability on time Cost planning, budgeting and comprehensive reporting functionality allows for a detailed controlling of

the project

Key process flows covered Creation of inquiry with linkage to project Easy Cost Planning Creation of quotation with reference to the inquiry Integration to the project system including calculation and scheduling functionalities Controlling and reporting along the complete process

Engineer-to-Order (ETO) – Quotation Processing (232)


Purpose This scenario describes the order processing in a standard Engineer-to-Order (ETO) environment. SAP Project System is used to control the whole process, from the SD requirement to planning,

purchasing, production and delivery. SAP Project-Oriented Procurement (ProMan) is used as an advanced tool to control the

planning/purchasing steps in the order procedure.

Benefits Project structuring/execution via project system is used to control the collaboration between different

departments Milestone billing is used to control the progressive payment procedure, and track back the status of

the project Use of ProMAN to control and monitor the manufacture/procurement procedures centrally Assignment of personnel resources and technical documents possible Delivery the semi-finished goods via the project Handling the final assembly on customer site using network activity in the project

Key process flows covered Creation of sales order with reference to the quotation and billing milestones Use of ProMan for procurement process of components Assignment of personnel resources and time recording Assginment of technical documents Confirmation of project activities Subassembly for semifinished goods Delivery to customer

Engineer-to-Order (ETO) – Project Assembly (240)

Purpose This scenario focuses on different approaches to supply the production using Kanban-

controlled business processes. Comprehensive presentation of different Kanban processes

Benefits The replenishment process controls itself and manual posting is reduced as far as possible. Reduction in lead time and stock. Components are not procured before they are needed (just in time). Prevention of overproduction. Reduction of required storage space. Simple and transparent method of organization. Event control and alerting enable timely reaction to changes and issues in the production

process

Key process flows covered Creation an maintenance of Kanban control cycles Creating Planned Independent Requirements and Material Requirements Planning (Plant) Classic Kanban: External Procurement with scheduling agreements Classic Kanban with JIT calls, calculation and alerting Classic Kanban: In-house production (repetitive manufacturing) with quantity signal and

trigger point Classic Kanban: Stock transfer from warehouse with alerting Event-driven Kanban with packaging instructions and alerting Repetitive manufacturing backflush


Manufacturing with Kanban-supply into Production (233)

Purpose Forecasting level is the semifinished product. Planned independent requirements are

generated for the semifinished material. Semifinished product is manufactured in a Make-to-Stock production (MTS) environment. Production of the finished product is triggered by customer orders (MTO) having the

forecasted semifinished product as one component in its bill of material. Integration of main cost object controlling functions, such as preliminary costing and period-

end closing.

Benefits

Production triggered by a production plan Batch management included Forecast of semifinished products Make-to-order and Make-to-stock processes in one scenario

Key process flows covered Creating Planned Independent Requirements Material Requirements Planning at Plant Level In-House Production (subassembly – Make-to-stock) In-House final production (assembly –Make-to-order) Confirming Assembly Activities Sales Order processing


Planning and Processing of Semifinished Goods(234)

Purpose

This scenario enables you to produce more than one material within one production order, which is often required in disassembly processes, such as cutting of tin.

Benefits

One or more components are used as input materials in the same production order. Two or more materials are produced simultaneously All products are posted into storage within the same transaction, so that during production

execution value differences do not require different processes. The main production costs are distributed among the most important products, including

production variances Production orders can be settled during period-end closing

Key process flows covered Creation of production order for co-production Check of material availability Production order execution for co-production Production order settlement


Co-Product Manufacturing (235)

Purpose

This scenario enables you to produce tools in a MTS (Make-to-stock) environment. The tool product is manufactured anonymously and delivered to storage as a production resource tool.

Benefits

Tool production using MTS (Make-to-stock) production order processing Material requirements planning for the components Material staging for tool components Serial number assignment for tool product Equipment maintenance for tool product

Key process flows covered Creation of production order for tool production Check of material availability Production order execution for tool production Equipment maintenance for tool product


Tool Production (236)

Purpose

Sales order returns processing with quality management inspection lots. The creation of the return sales order references to the original billing document for the goods. The goods are shipped back and a return delivery is created with reference to the sales order. After quality inspection the goods are either returned to stock, scrapped, or returned to the vendor. A credit memo is created from billing, and posted to the customers account.

Benefits

Full integration of sales order returns and quality management Sales order returns are processed according to sales order reference to the original billing

document Credit memo is created and posted to customers account

Key process flows covered Creation of return order Creation of return delivery Quality inspection Release returns for billing and billing


Sales Returns with Quality Management (QM) (237)

Purpose

This scenario deals with cash only payment transaction for the sales of material to a customer.

The cash sales process is used when the customer places the sales order and picks up and pays for the goods at the same time. The system automatically proposes the current date in the sales order as the date for the delivery and billing. Once the sales order is saved, the system automatically creates a delivery.

Benefits

Sales and delivery are created in one step Optional batch management

Key process flows covered Creation of sales order and delivery (automatically) Check batches (optional) Post goods issue Billing


Cash Sales Order (238)

Purpose

This scenario is an example of how warehouse management (WM) can be used. It does not cover all possible warehouse management processes for complete WM implementation (for example inventory counting is not part of this scenario).

WM is used for the storage of raw materials and finished goods.

Internal transfer orders are used for put away, internal transfers and removal from storage.

Benefits This scenario shows the integration of WM with inbound logistics, production and outbound

logistics

Key process flows covered Purchasing process with transfer orders Production order creation and processing of material movements with WM Sales order processing and WM transfer orders


Shipping and Receiving with Warehouse Management (239)

Purpose The scenario Make-to-Stock (MTS) Production with order split focuses on options

how to split an existing production order for which processing may have already begun into two separate production orders. These production orders are then executed separately from a logistics perspective.

Benefits Increased flexibility for the production planner to react to unplanned events on the

shop floor, changed customer requirements or repriorization of production orders. Better cost transparency considering real shop floor-driven plan changes Reliable batch traceability information also after production order split

Key process flows covered Allows split of already partially confirmed production order Allows split to put material on stock Visualization of split history Supports meaningful comparison of planned vs actual cost on parent & child Fair split of planned cost between parent & child Update batch traceability during split


Make-to-Stock Production with Order Split (248)

Purpose Outsourced manufacturing enhances the typical subcontracting and external

processing processes with advanced features which are part of EhP 4.

Benefits Serial Numbers Assignment in Procurement Subcontracting ASN with components Monitoring of whole process with subcontracting process Material numbers can be transferred to purchase orders Usage of subcontracting stock In-time consumption posting of components Inventory Reports Monitoring of Batches


Outsourced Manufacturing (249)

Purpose This scenario describes advanced sales order returns processing with material

inspection. The creation of the return sales order references to the original billing document for the goods. The goods are shipped back and a return delivery is created with reference to the sales order. After material inspection and decision on follow-up activities a credit memo is created and posted to the customers account.

Benefits Manage customer returns with advanced functions that provide end-to-end

support for the returns process Sales order returns are processed according to sales order reference to the

original billing document Automatic Creation of follow-up documents after material inspection Credit memo is created and posted to customers account Monitoring of the whole return process

Key process flows covered Creation of return order and return delivery Quality Evaluation and automatic creation of follow-up documents Release returns for billing and billing Process Monitoring


Advanced Customer Returns Management (250)

Purpose This scenario focuses on the combination of third-party order processing

and subcontracting Sold Products are finished by a subcontractor and sent to the customer

directly by the vendor

Benefits Reducing stock and cost, increasing efficiency Combination of third-party process with subcontracting functionality Handover of customer’s requirements directly to external supplier Invoice from subcontractor bases on external services

Key process flows covered Third Party Sales Order Convert Purchase Requisitions to Purchase Order Shipping of components to subcontractor Post Statistical Goods Receipt with consumption of components Invoice verification Billing


Third-Party Order Processing with Subcontracting (252)

Purpose This scenario focuses on the Kanban-supported production planning and

optimization in repetitive manufacturing By using a special algorithm the production process is optimized and demand

fluctuations are balanced

Benefits Stabilization and optimization of production process Transfer of uneven customer demands in smooth, stable and predictable production

schedule Optimization of stocks and value flow Components are not procured before they are needed (just in time). Prevention of overproduction. Reduction of required storage space. Event control enables timely reaction to changes and issues in the production

process

Key process flows covered Creation of strongly fluctuating planned independent requirements Production Planning in repetitive manufacturing Heijunka sequencing and optimization Kanban Processing with repetitive manufacturing backflush Production Schedule Evaluation Postprocessing


Lean Manufacturing: Heijunka Leveling (253)

Records Management (661)

Note: Additional license fees may arise when records management is used in a productive environment

Purpose This scenario focuses on the creation of customer order records and equipment

records It describes records management process in a typical project-oriented

manufacturing environment

Benefits Fast access to relevant information leveraging workspace efficiency and

response time to customer inquiries Non-redundant, reliable information storage with efficient usage of resources Accelerated implementation of business processes by leaded process

automation and early time-to execution Decreasing information management costs by using controlled distribution,

updates and archiving processes Usage of records management enables focusing on the core business


Purpose

The online split is provided with the new General Ledger Accounting. Documents are enhanced with additional account assignment objects, or additional postings

are done which split the original postings into lines referring to the account assignment objects.

Account assignment objects can be defined according to selected dimensions. In SAP Best Practices the dimensions are profit centers and segments.

Benefits The postings are done in real time (online). It is possible to draw up complete financial statements for the selected dimensions at any

time (segment reporting).

Key Points The online split is provided with the new General Ledger Accounting. The online split is based on segments. The online split must be activated before the start of postings in the client. Postings done

before can cause subsequent online split errors (see also note 891144).


Activate Document Splitting for Discrete Manufacturing (245)

Legend

Symbol Description Usage Comments

Band: Identifies a user role, such as Accounts Payable Clerk or Sales Representative. This band can also identify an organization unit or group, rather than a specific role.

The other process flow symbols in this table go into these rows. You have as many rows as required to cover all of the roles in the scenario.

Role band contains tasks common to that role.

External Events: Contains events that start or end the scenario, or influence the course of events in the scenario.

Flow line (solid): Line indicates the normal sequence of steps and direction of flow in the scenario.Flow line (dashed): Line indicates flow to infrequently-used or conditional tasks in a scenario. Line can also lead to documents involved in the process flow.

Connects two tasks in a scenario process or a non-step event

Business Activity / Event: Identifies an action that either leads into or out of the scenario, or an outside Process that happens during the scenario

Does not correspond to a task step in the document

Unit Process: Identifies a task that is covered in a step-by-step manner in the scenario

Corresponds to a task step in the document

Process Reference: If the scenario references another scenario in total, put the scenario number and name here.


Sub-Process Reference: If the scenario references another scenario in part, put the scenario number, name, and the step numbers from that scenario here


Process Decision: Identifies a decision / branching point, signifying a choice to be made by the end user. Lines represent different choices emerging from different parts of the diamond.

Does not usually correspond to a task step in the document; Reflects a choice to be made after step execution

Symbol Description Usage Comments

To next / From last Diagram: Leads to the next / previous page of the Diagram

Flow chart continues on the next / previous page

Hardcopy / Document: Identifies a printed document, report, or form

Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines

Financial Actuals: Indicates a financial posting document


Budget Planning: Indicates a budget planning document


Manual Process: Covers a task that is manually done

Does not generally correspond to a task step in a document; instead, it is used to reflect a task that is manually performed, such as unloading a truck in the warehouse, which affects the process flow.

Existing Version / Data: This block covers data that feeds in from an external process

Does not generally correspond to a task step in a document; instead, this shape reflects data coming from an external source; this step does not have any incoming flow lines

System Pass / Fail Decision: This block covers an automatic decision made by the software

Does not generally correspond to a task step in the document; instead it is used to reflect an automatic decision by the system that is made after a step has been executed.

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