scm2010_deridder_howtodesign
DESCRIPTION
How to desig, Integrate and deploy a Sales Order Process for Configurable Products in 60 daysTRANSCRIPT
0© SAP 2010 / 0© SAP AG 2010 / 0
How to Design, Integrate, and Deploy a Sales Order Process for Configurable
© 2010 Wellesley Information Services. All rights reserved.
and Deploy a Sales Order Process for Configurable Products in 60 Days
Jan De RidderAccenture
In This Session …
• We will demonstrate the use of variant configuration in SAP
� This presentation is built around a fictitious project, but based
on a real client in a completely different industry
� The project was delivered in 60 man days from study to go-live
• We will discuss the setup of three SAP flows for sales,
production, and subcontracting
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• We will use primarily the following modules:
� SD
� PP
� MM
� LO-VC
What We’ll Cover …
• Business case
• Business requirements
• High-level solution overview
• SAP configuration
• SAP demo
• Wrap-up
3
• Wrap-up
Company: Paint Inspiration
• We will discuss the company “Paint Inspiration,” a company that
produces and sells paint
• The company has two factories, each linked to a local sales office:
� 1 in Belgium serving mainly West Europe
� 1 in US serving mainly North America
• Both factories produce similar products
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Both factories produce similar products
• The company has two divisions:
Paint production Bottling
Volumes High Low
Margins Low High
Production process Process industry Discrete mfg
Customers Industry, wholesalers, ‘home depot’ … End-users (painters)
Turnover share 80% 20%
Project Rationale
• The company had an SAP implementation but only for the paint
production division
• The bottling division was not on SAP:
� No integration with paint production, planning of requirements
for paint
� Manual bookings, high workload for accounting people during
month-end closing period
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month-end closing period
� Inaccurate stock follow up
� Plant controller has no grip on the sales and production
processes
Management decided that the bottling division may
be integrated in the SAP ERP system
Defining the Project Scope
• The company was in a cost-cutting campaign and asked the
consultant for a low-cost project/solution
• As a pilot, only the European plant was in scope of the initial
implementation
• The SAP processes of the industrial paint division could not be
taken over
No fit with the business processes of the bottling division
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� No fit with the business processes of the bottling division
� Too many transactions for the operators
• The only way to meet the budget constraints was to go for a 100%
standard SAP solution
What We’ll Cover …
• Business case
• Business requirements
• High-level solution overview
• SAP configuration
• SAP demo
• Wrap-up
7
• Wrap-up
Study Phase: Define Business Processes and Requirements
• The company identified three business flows:
� Sales of in-house produced material
� Major flow where the bottled paint is produced in-house and shipped to the customer
� Sales of sub-contracted material, direct shipment
� Production is subcontracted to US plant if the customer is based in North America
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based in North America
� Production is subcontracted to third-party subcontractor if there is no own capacity
� The subcontractor ships goods directly to the customer
� Sales of sub-contracted material, shipment via own plant
� Material comes to the plant before shipping to the customer. Mainly done to re-label or to avoid subcontractor – customer contact.
• All flows are 100% Make-to-Order (MTO)
Production Process
• The production process is simple:
� Color pigments are added to the white paint
� Paint is mixed in a big mixer
� The colored paint is poured in the container
• Customer requirements when placing an order:
� Total volume
Color
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� Color
� Intensity
� % pigments: red, blue, and yellow
� Packaging
� Material (metal/plastic)
� Dimensions
What We’ll Cover …
• Business case
• Business requirements
• High-level solution overview
• SAP configuration
• SAP demo
• Wrap-up
10
• Wrap-up
Three Process Flows
• We distinguish three different flows (all MTO):
� In-house production
� Subcontracting with direct shipment from subcontractor to
customer
� Subcontracting with plant as forwarder
• This separation was driven by the fundamental differences in
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This separation was driven by the fundamental differences in
configuration required for these three flows
• On these flows are some (non-fundamental) variances:
� Raw materials in stock or to be ordered
� Subcontractor uses own raw materials or consigned from Paint
Inspiration (components provided to vendor)
Three Process Flows (cont.)
• The three flows are harmonized; same transactions, same
materials, same users, etc.
• Variant configuration is used in the three flows:
� It is the data carrier through the different modules
� Lean master data setup
� Automation throughout the flow, including calculations
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Automation throughout the flow, including calculations
• Each flow starts with a sales order. To trigger a specific flow, the
user has to select the relevant order type:
� ZP01: In-house production
� ZP02: Subcontracting direct
� ZP03: Subcontracting indirect
For the user, the sales order type is the only main
decision point between the three flows
Process Flow: In-House Production
Sales order
Production order Sales order stock
Delivery Invoice
MRP Planned order
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MRP
Purchase req
Raw materials
Purchase order
Raw materials
Intermediate product
Process Flow: Subcontracting Direct Shipment
Sales order
Purchase order
Subcontracting
Goods Receipt
(w/o qty update)
Invoice
Invoice verificationGoods Issue
(stock @ vendor)
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MRP
Purchase req
Raw materials
Purchase Order
Raw materials
GR at own plant
GR @ subco
(stock @ vendor)
Delivery to subco
GI (stock @ vendor)
Process Flow: Subcontracting via Own Plant
Sales order
Purchase order
Subcontracting
Goods Receipt
(with qty update)Sales order stock
Goods Issue
Delivery Invoice
Invoice verification
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Subcontracting
MRP
Purchase req
Raw materials
Purchase Order
Raw materials
GR at own plant
GR @ subco
(stock @ vendor)
Delivery to subco
GI (stock @ vendor)
(stock @ vendor)
What We’ll Cover …
• Business case
• Business requirements
• High-level solution overview
• SAP configuration
• SAP demo
• Wrap-up
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• Wrap-up
SAP Configuration
• Variant configuration
� In most companies, the setup of variant configuration is
considered as “customizing” (not done by end-users), but in
SAP, it is all defined as master data (not in SPRO and not
transportable via normal procedures)
� The only variant configuration customizing objects in SPRO are
authorizations and statuses
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authorizations and statuses
• Master data
� Master data is another determent for the flow, especially in the
PP module where master data (BOM, routing, etc.) controls the
process flow
SAP Configuration (cont.)
• Standard customizing
� The setup of SD, MM, PP, LE and FI/CO
� For this setup, the amount of standard customizing is extensive
and can be found in the take-home customizing guide
� In this presentation, only a small selection of key elements for
the flow and integration will be shown
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Setup Variant Configuration
Configurationprofile
Class 300 Pricing
Used in our flow Not used in our flow
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ProductVariant table
Super BOM Dependencies Super routing
Variant function
Product
• Only one configurable material was created: Bottled paint
• Material type: KMAT – customizing
You can also use a Z material
type, but make sure the flag
“Material is configurable” is
flagged
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Configuration Profile
• The behavior of the variant configuration in the sales order is
controlled by the configuration profile
One configuration profile for the end-
product is needed
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Several dependencies are assigned
to the configuration profile. This
means that they are always active
during configuration and not
triggered by a specific characteristic.
Class 300
• 3 groups of
characteristics:
� Group 1: reference
characteristics to use
in dependencies
� Group 2:
characteristics to
model the product
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model the product
� Group 3: calculated
characteristics to be
used in the rest of
the process
• All characteristics are
added to the 300 class
to be available in variant
configuration
Class 300 (cont.)
• Characteristics group 1: reference characteristics
� These characteristics are linked to a field in a database table
� They are filled automatically during configuration and are not
editable
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The formatting is taken over from the database field
Characteristic Table Field Function
PI_CUSTOMER VBAK KUNNR Get default values from variant table
PI_ORDER_TYPE VBAK AUART Distinction between production and subco
Class 300 (cont.)
• Characteristics group 2: modeling characteristics
� The values will be entered by the user in order processing
� The modeling parameters are completely fictitious for the paint industry and are only used to demonstrate the SAP functionalities
Characteristic Function
PI_PACK_REQUIRED Only relevant in the subco flows: determines if the subcontractor uses packaging
from Paint Inspiration or own packaging. Only shown if order type is ZP01 or ZP02
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from Paint Inspiration or own packaging. Only shown if order type is ZP01 or ZP02
Allowed values: 0 and 1
PI_PACK_MATERIAL The type of packaging material
Allowed values: S – steel and P – Plastic
PI_PACK_FORMAT The format of the packaging material
Allowed values: C – cylinder and R – rectangular
PI_PACK_SIZE1/2/3 The dimensions of the packaging
PI_COLOR_DENSITY The concentration of the color on a scale of 0 to 100%
PI_FACTOR_RED
PI_FACTOR_BLUE
PI_FACTOR_YELLOW
The concentration of the 3 individual basic colors (blue, red and yellow) on scales of
0 to 100%
Class 300 (cont.)
• Characteristics group 3: calculated characteristics
� The values of these characteristics are calculated by
dependencies based on the modeling characteristics
Characteristic Function
PI_PACK_VOLUME The volume per packaging unit is calculated from the dimensions and will be used
to calculate the number of packages per order
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• Divide by 1,000 to go from cm³
to L
• Dependency type is procedure
• Assigned to the configuration
profile
Class 300 (cont.)
• Characteristics group 3: calculated characteristics
Characteristic Function
PI_BLUE_GRAM_PER_LITER
PI_RED_GRAM_PER_LITER
PI_YELLOW_GRAM_PER_LITER
For each pigment the required quantity in grams is calculated to get the
desired color requested by the customer. The assumption is that for a
fully concentrated paint with one basic color, 50 g of pigment material is
needed.
These quantities are used later to calculate the BOM item quantities.
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These quantities are used later to calculate the BOM item quantities.
• 1 procedure per basic color
• Assigned to the configuration
profile
Variant Table
• Paint Inspiration has mainly returning customers who have
recurring orders. We use a variant table to avoid re-entering the
same parameters for each order.
� The key field is “customer,” the sold-to party in the sales order.
For this we used the reference characteristic PI_CUSTOMER.
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Never use blank values in the
table. Dependencies will not
work! Use 0 instead.
Variant Table (cont.)
• To get the default values from the variant table in the variant
configuration, we use a dependency with two parts:
� Part 1: Read data from the table based on the key (sold-to)
� Part 2: Default these values in the variant configuration
Part 1: The defaults for the sold-to are stored in
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sold-to are stored in intermediate characteristic
Part 2: The values are defaulted in the VC characteristic
Without the “default” function,
the user can not change the
defaulted values!
Super BOM — Overview
• The super BOM is a key element in the integrated flow
� The super BOM has usage “3” (universal) and is used in SD, MM, and PP
� It consists of three component groups selected by the variant configuration
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Component Selection Quantity
Basic white paint • Only for in-house production No dependency: 1:1 with header Qty
Pigment (blue/red/yellow) • Only for in-house production
• Qty > 0
Qty derived from VC � g/L calculated
Packaging • Always for in-house production
• For subcontracting: only if indicated in VC
N/A for the phantom component
Component Selection Quantity
PACK-01 Based on the
dimensions
entered in the VC
Total volume of order divided by volume
per packaging unit. This volume is
calculated in VC based on the dimensions
of the packaging.
PACK-02
PACK-03
…
The packaging is a phantom
component. This allows to re-use
in other BOM’s with central
maintenance of the packing BOM
Super BOM — Basic White Paint
• Component basic white paint
� Requirement for the industrial paint division
� Only relevant for the in-house production, the subcontractor
uses his own paint
The dependency type is “selection condition”
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Use object variable PARENT: The configuration of the header material is used
The dependency is assigned to the BOM Item
Super BOM — Pigment Blue/Red/Yellow
• Pigments are raw materials; procured externally. The BUOM is gram.
� Setup for the blue pigment:
Selection condition
The required quantity (calculated in the
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(calculated in the configuration) is written to the item quantity of the BOM item
We created a reference characteristic to the BOM Item quantity. This will update the database field; a standard SAP functionality to control the item quantities via variant configuration.
Super BOM — Packaging
• For the packaging, we use a phantom material:
For phantom materials, the special procurement key must be 50.
The phantom indicator is automatically flagged in the BOM item
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The phantom item in a BOM (also called “phantom assembly”) has its own
BOM with “real” materials as components. At the time of explosion (i.e., in
production order or purchase order) the phantom BOM is exploded but the
phantom material will not be part of the component list.
You can use phantom assemblies for groups of components which are part
of many different BOMs. This allows central maintenance without having a
dummy material in the component lists at the time of explosion.
Super BOM — Packaging (cont.)
The phantom material must also have configuration profile
A procedure (assigned to the configuration profile) will copy the VC values from the header material to the phantom material. Needed for the packing component selection.
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The BOM of the phantom material:
Super BOM — Packaging (cont.)
• These components are not selected via dependencies, but by
another standard SAP feature:
In the BOM item the flag “as selection condition” is flagged, the class type is 001.
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An additional class is created (type 001) with the dimension’s characteristics of the VC. The dimensions of the packing materials are maintained via MM02.
The selection is based on the variant configuration of the BOM
header material. In our case, this is the phantom material
which is not configured. For this reason we copy the variant
configuration of the root material to the phantom item.
SD Customizing
• Based on the sales order type, the following SD customizing objects are selected automatically
• We will demonstrate how this (mainly) SD customizing controls all processes in SD, MM, and PP
Order type� Relevant for delivery
� Order/delivery-based billing
� Variant configuration active
SD
SD
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Item category
Schedule line
category
Account assignment
category
Requirements Class
� Variant configuration active
� Relevant for billing
� Relevant for delivery + movement type
� Purchase Order type + Item Category
� Financial posting
� Invoice Receipt/Goods Receipt
SD
SD
MM
SD� Production order type
� Sales order stock
Integration MM
Integration MM
Integration PP
SD Customizing — Sales Area and Order Type
Paint Inspiration has two sales areas: for the
consumer paint (this setup) we created distribution
channel P2. This allows us to make a completely
different SD setup and is a key distinction in SD
reporting.
IMG � Sales and Distribution � Sales � Sales Documents � Sales Document Header � Define Sales Document types
IMG � Enterprise Structure � Assignment � Sales and Distribution � Setup sales area
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Order Type Delivery type Order Rel. Billing Del. Rel. Billing
ZP01 – In-house production LF N/A F2
ZP02 – Subco direct N/A F2 N/A
ZP03 – Subco indirect LF N/A F2
We have three sales order types, with almost
identical customizing
SD Customizing — Item Category/Link Schedule Line Category
Activates the variant
configuration in the sales order
Billing relevance is specific per flow.
• ZP01 & ZP03 ���� A “delivery related”
• ZP02 ���� C “order related”
IMG � Sales and Distribution � Sales � Sales Documents � Sales Document Item � Define Item Categories
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IMG � Sales and Distribution � Sales � Sales Documents � Schedule Lines � Assign Schedule Line Categories
Each item category is 1:1 linked to a
schedule line category
SD Customizing — Item Categories
IMG � Sales and Distribution � Sales � Sales Documents
� Schedule Lines � Define Schedule Line Categories
Only movement type for delivery
is relevant. No integration with
MM.
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Integration with MM: Standard
PO must be created with item
category subcontracting
Link with Account
Assgt. Cat.
SD Customizing — Account Assignment Category
SPRO � MM � Purchasing � Account Assignment � Maintain Account Assignment Categories
We have a new AAC for the subco direct flow.
No goods receipt is done (the goods go
directly to the customer) but we do need a
MIGO GR transaction to consume the
components at vendor (subcontracting).
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The AAC is MM customizing which controls the following
parameters of the PO item (relevant for this flow):
• Goods receipt
• Invoice Receipt
• FI/CO booking
For the subco indirect flow, we use the standard AAC “M” (Indicates
customer without KD-CO)
SD Customizing — Requirements Type/Class
IMG � SD � Basic functions � Availability Check and Transfer of Requirements � Transfer of Requirements � Define requirements classes
Requirements class Z40 for in-house production
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In-house production; the order type is the
production order type! Via this setting, we
specify that a production order must be
created.
In all flows, the stock type is “E”
���� sales order stock
All costs are assigned to the
sales order
SD Customizing — Requirements Type/Class (cont.)
IMG � SD � Basic functions � Availability Check and Transfer of Requirements � Transfer of Requirements � Define requirements classes
Only difference is that we have
no order type; no production
order created
Requirements class Z41 for subcontracting
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IMG � SD � Basic functions � Availability Check and Transfer of Requirements � Transfer of Requirements � Define requirements types
A requirements class is linked to
a requirements class (n:1)
IMG � SD � Basic functions � Availability Check and Transfer of Requirements � Transfer of Requirements �Determination Of Requirement Types Using Transaction
Each item category is linked with
a requirements type (n:1)
Other Customizing
IMG � Production � Shop Floor Control � Master Data � Order � Define Order types
In the production order type, the
settlement profile is SD1 – the costs of
the orders will be settled to the sales
order
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The setup of PP and other modules is similar to a normal MTO and
subcontracting setup. There are no specific variant configuration
settings. Details can be found in the configuration guide.
What We’ll Cover …
• Business case
• Business requirements
• High-level solution overview
• SAP configuration
• SAP demo
• Wrap-up
43
• Wrap-up
SAP Demo
• Three flows:
� In-house production
� Subcontracting direct
� Subcontracting indirect
• Not all the process steps will be shown in all three flows, but all
steps will be shown at least once in one of the flows
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steps will be shown at least once in one of the flows
In-House Production
• We will first show the in-house production flow
Sales order
Production order Sales order stock
Delivery Invoice
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Production order Sales order stock
MRP
Purchase req
Raw materials
Purchase order
Raw materials
Planned order
intermediate product
Create Sales Order
VA01 – create sales orderThe bottling department has a specific distribution channel, forming a separate sales area. This allows specific customizing and reporting. This could also be done via a separate division.
We use one generic, configurable, material that is used for all customers and for all flows
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Create Sales Order (cont.)
VA01 – create sales order
Maintain variant configuration
The defaults come from the variant table, looked up via the sold-to number. The defaults can be changed in this screen.
The modeling characteristics. These define the product the customer is ordering.
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the product the customer is ordering.
The calculated characteristics which will be used for the BOM explosion in the production order. These could also be hidden.
Create Sales Order (cont.)
VA01 – create sales order
Complete relevant data
For the demo, we use a very simple
pricing scheme with only one condition
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The standard item text “Production memo” is
copied into the production order and can be
used as a communication means between sales
and production
Lookup Production Order
CO46 – order progress report
With this transaction, we can follow up the
MTO flow, starting from the sales order
In a productive environment, the production department
will use the transaction COOIS to create the list of new
production orders. This will be used as a work list.
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We jump to the stock/requirements list
where we can see the production order
number and the reserved component
quantities
Change and Release Production Order
CO02 – change production order
The order is to produce the material
“PAINT,” our generic configurable
material.
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Because it’s an MTO flow, you can see
immediately the sales order number and
customer name.
In the tab “Production memo” you can see
the text we entered in the sales order.
Change and Release Production Order (cont.)
CO02 – change production order
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In the production order, we can also see the
variant configuration. This is for information
purposes only and could be printed on shop
floor paper (together with the production memo
text).
Change and Release Production Order (cont.)
CO02 – change production orderIn the components view, we can see the
components that were selected by the
dependencies. The quantities of the pigment and
the packaging are also calculated via
dependencies. The user must select the batches
via batch determination.
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The last step is to release the order
Confirm Production Order
CO11N – confirm production order
We confirm the full order quantity in one
step. To keep the demo simple, we don’t
confirm scrap, machine time, labor time,
etc.
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In the goods movements screen, the
components with quantities are filled
automatically. We check the data and
save. Now the order is confirmed and the
goods movements posted.
Settle Production Order
KO88 – order settlement
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This step is done at month-end
closing. Because it’s an MTO
flow, the costs will be settled to
the sales order.
Settle Production Order (cont.)
CO03 – display production order
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In the example is the cost of raw
materials. By double-clicking we see the
details.
The costs are settled to
the sales order
Settle Production Order (cont.)
VA03 – display sales order
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As a result, we can see the costs of the
production order in the sales order. This will
be settled to CO-PA where the costs can be
compared with the revenues of the sales
order. This will lead to margin reporting based
on individual sales orders.
Create Delivery, Goods Issue, and Create Invoice
VL01N – create delivery & goods issuePost goods issue
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VF01 – create invoice
Subcontracting Direct
• In the subcontracting direct flow, the production is outsourced
• We will have a purchase order instead of a sales order
Sales order
Goods Receipt
Invoice
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Purchase order
Subcontracting
Goods Receipt
(w/o qty update)
MRP
Purchase req
Raw materials
Purchase Order
Raw materials
Invoice verification
GR at own plant
GR @ subco
(stock @ vendor)
Delivery to subco
GI (stock @ vendor)
Goods Issue
(stock @ vendor)
Create Sales Order
VL01N – create delivery & goods issueWe choose another order type
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In customizing we specified that, for
this flow, a purchase requisition
must be created. Thanks to the
integration in SAP, the user can
enter the PR data already in the
sales order via this pop-up.
Create Purchase Order
VA03 – display sales order
In the sales order schedule line, we can see
the PR number
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Create the purchase order by dragging the PR
in the basket.
ME21N – create purchase order
Create Purchase Order (cont.)
ME21N – create purchase order
Click Components to see the
material to be shipped to the
subcontractor. The components
are from the BOM, selected by
the configuration.
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Press Configuration to see the
variant configuration entered
in the sales order
Ship Components to Subcontractor
ME2O – subcontracting stock monitorComponent PACK01 is in balance:
- Purchase order for 100 PC
- Stock of 100 PCThe stock can be posted directly
(Post Goods Issue) or via an
outbound delivery.
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In our demo, we use component PACK07:
- Requirement of 6 PC
- 0 stock
Replenishment needed
Ship Components to Subcontractor (cont.)
MMBE – stock overview
ME2O – subcontracting stock monitor
In the standard stock lists,
you can see the stock at
vendor
In the subcontract stock
monitor, both components
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monitor, both components
are in balance
Goods Receipt
MIGI – Goods receipt
At goods receipt we will do two postings:
- The 101 movement: receive the finished products. In this flow (subcontracting direct) the goods are not posted in
our stock. They are delivered directly to the customer.
- The 543 movement: the stock at vendor is consumed. The quantity can be adjusted in the MIGO transaction.
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Final Steps
• The final steps in the process are:
� Enter incoming invoice (transaction MIRO)
� Create outgoing invoice (transaction VF01)
� Costs from the purchase order settled to the sales order
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Subcontracting Indirect
• This flow is very similar to the subcontracting direct flow
• Differences
� Stock is received in the BE99 plant; not directly at customer
� An outbound delivery is created to ship the stock from plant
BE99 to the customer
� The sales invoice is delivery-based and not order-based
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The sales invoice is delivery-based and not order-based
What We’ll Cover …
• Business case
• Business requirements
• High-level solution overview
• SAP configuration
• SAP demo
• Wrap-up
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• Wrap-up
Resources
• SAP Best Practices: Make-to-Order Production with Variant
Configuration
� http://help.sap.com/bp_bl604/BBLibrary/HTML/147_EN_DE.HTM
• SAP courses PLM 140 & PLM 143
� www.sap.com/services/education/index.epx
• Variant Configuration (LO-VC)
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Variant Configuration (LO-VC)
� http://help.sap.com/saphelp_erp60_sp/helpdata/en/92/58d45541
7011d189ec0000e81ddfac/frameset.htm
• Configuration Workgroup
� www.configuration-workgroup.com
Resources (cont.)
• SAP Variant Configuration Technology blog
� http://sapvariantconfiguration.blogspot.com
• Uwe Blumöhr, Manfred Münch, Marin Ukalovic, Variant
Configuration with SAP (SAP Press, 2009).
• A full list of IS-MILLS/DIMP functionalities
� http://help.sap.com/saphelp_dimp50/helpdata/EN/4e/1796374b0
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http://help.sap.com/saphelp_dimp50/helpdata/EN/4e/1796374b0
88e5ce10000009b38f8cf/frameset.htm
7 Key Points to Take Home
• Stick to standard SAP: Variant configuration offers enough flexibility and your budget will be surprisingly low
• Have somebody on the project who knows the different modules in scope: this is key for the integration
• It’s not required to use only one material in your system: You can use different configurable materials for different groups of materials
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materials
• If you have the same components in all your BOMs, you should switch to configurable phantom assemblies
• Make use of variant tables; it’s the best to way to use defaults in the sales order variant configuration
• Link your variant table to a database table when it’s getting big and hard to maintain
• Foresee at least one custom build report where users can see sales orders with configuration
Disclaimer
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and service names mentioned are the trademarks of their respective companies. Wellesley Information Services is neither owned nor controlled by
SAP.
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