scm300 manufacturing overview

SCM300Manufacturing Overview

SAP SCM

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Participant HandbookCourse Version: 92Course Duration: 3 Day(s)Material Number: 50093459

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About This HandbookThis handbook is intended to complement the instructor-led presentation of thiscourse, and serve as a source of reference. It is not suitable for self-study.

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About This Handbook SCM300

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iv 2009 SAP AG. All rights reserved. 2009

ContentsCourse Overview ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Course Goals .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viiCourse Objectives ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

Unit 1: Introduction..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Production types of the applications SAP ERP and SAP SCM...2

Unit 2: Order-Controlled Production with Production Orders..11Order-Controlled Production with Production Orders .. . . . . . . . . . . 12Elements, Functions, and Processing of a Production Order ... 22

Unit 3: Order-Controlled Production with Process Orders..... 81Order-Controlled Production with Process Orders .. . . . . . . . . . . . . . 82Elements, Functions, and Processing of a Process Order .. . . . . 93

Unit 4: Repetitive Manufacturing..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Characteristics of Repetitive Manufacturing.. . . . . . . . . . . . . . . . . . . . .152Functions and Process Steps in Repetitive Manufacturing.. . . .169

Unit 5: KANBAN...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Features of the KANBAN Procedure .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .208The KANBAN Procedure.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212

Unit 6: Project-Oriented Production (optional) ... . . . . . . . . . . . . . . . 225Characteristics of Project-Oriented Production ... . . . . . . . . . . . . . . .226Process Flow of Project-Oriented Production .. . . . . . . . . . . . . . . . . . .232

Unit 7: Integration to process control level (optional) . ... . . . . . 253PP-PDC Interface .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254Process Management/Process Integration ... . . . . . . . . . . . . . . . . . . . .259SAP OPC Data Access ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266SAP MII in Shop Floor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272

Appendix 1: Summary ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Appendix 2: References ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

2009 2009 SAP AG. All rights reserved. v

Contents SCM300

vi 2009 SAP AG. All rights reserved. 2009

Course OverviewManufacturing is a component of the SAP SCM (Supply Chain Management) andSAP ERP (Enterprise Resource Planning) applications within the SAP BusinessSuite. You can use manufacturing to manage all the manufacturing activitieswithin your supply chain in one integrated system from planning throughexecution to analysis. The focus of this course is execution. The following topicsare dealt with, in particular:

Order-Controlled Production with Production Orders Order-Controlled Production with Process Orders Repetitive Manufacturing KANBAN Project-Oriented Production (optional)

Target AudienceThis course is intended for the following audiences:

Project team members and key users (people from relevant departments)who are responsible for implementing shop floor control within the SAPBusiness Suite applications

Course PrerequisitesRequired Knowledge

SAPSCM: mySAP SCM Overview

Recommended Knowledge

PLM100 Lifecycle Data Management SCM100 Supply Chain Planning Overview (ERP) SCM200 Supply Chain Planning Overview (SCM)

Course GoalsThis course will prepare you to:

Understand the positioning, integration, and functions of the manufacturingarea within the SAP ERP (Enterprise Resource Planning) and SAP SCM(Supply Chain Management) applications

Obtain an overview of the supported production types

2009 2009 SAP AG. All rights reserved. vii

Course Overview SCM300

Course ObjectivesAfter completing this course, you will be able to:

Describe basic shop floor control procedures and functions and understandsimple scenarios in the SAP System

SAP Software Component InformationThe information in this course pertains to the following SAP Software Componentsand releases:

ERP 6.0Enhancement Package 4 SAP SCM 7.0

viii 2009 SAP AG. All rights reserved. 2009

Unit 1Introduction

Unit OverviewManufacturing types of applications SAP ERP and SAP SCM

In this unit, you will learn about the manufacturing types within the SAP BusinessSuite.

Unit ObjectivesAfter completing this unit, you will be able to:

you will be able to name the production types that are supported within theSAP Business Suite.

Unit ContentsLesson: Production types of the applications SAP ERP and SAP SCM ...2

2009 2009 SAP AG. All rights reserved. 1

Unit 1: Introduction SCM300

Lesson: Production types of the applications SAP ERPand SAP SCM

Lesson OverviewIn this lesson, you will learn about the production types that are supported withinthe SAP Business Suite.

Lesson ObjectivesAfter completing this lesson, you will be able to:

you will be able to name the production types that are supported within theSAP Business Suite.

Business ExampleYour company implements the SAP Business Suite. You are either a member ofthe project team responsible for implementing the shop floor control functionsor you are in the production department. You use various scenarios to gain anoverview of the possibilities and functions of the supported production types.

Overview of SAP applications

Figure 1: SAP ERP Application Overview


SCM300 Lesson: Production types of the applications SAP ERP and SAP SCM

As part of the long-term product strategy of SAP, you are offered an SAP BusinessSuite that comprises a number of applications.

The Enterprise Resource Planning (ERP) application is a comprehensiveapplication that enables a company to efficiently plan, control and monitorcomplex delivery, procurement and production networks.

This application supports a synchronized and close interaction between alldepartments involved (and all people involved) within a logistics chain.

Customers, sales, production planning, manufacturing, warehouse management,purchasing, and vendors are all included in this complete solution.

The SAP ERP application includes a number of areas (see above).

You will find further information about the individual components of the SAPERP application at

http://www.sap.com/solutions/businessmaps/solutionmaps/

and also here, under Cross-Industry Business Maps.

Figure 2: SAP SCM Application Overview

SAP Supply Chain Management (SCM) is a comprehensive applicationthat enables a company to efficiently plan, implement and monitor complexdelivery, procurement and production relationships (supply chains).

This application supports a synchronized and close interaction between alldepartments involved (and all people involved) in a logistics chain.



Customers, sales, production planning, manufacturing, warehouse management,purchasing, and vendors are all included in this complete solution.

In particular, the processing of cross-company processes and the collaborativeplanning and procurement processes, which also enable a connection to openmarket places, are a main feature of this application.

The SAP SCM application includes a number of areas (see above).

You will find further information about the individual components of the SAPSCM application at

http://www.sap.com/solutions/businessmaps/solutionmaps/

and also here, under Cross-Industry Business Maps.

Figure 3: SAP Components

In-house production is largely supported by the SAP component SAP ECC(formerly R/3).

SAP SCM provides considerably enhanced planning tools (Advanced Planningand Optimization (APO), an enhanced inventory function (Supply NetworkCollaboration (SNC)) and Event Management (EM).

SAP BW (Business Information Warehouse) is used to separately store data forvariable evaluations.

Interfaces for realizing the integration of ECC with SCM, BW or CRM areprovided with an appropriate plug-in.

The interface between ECC and SCM (APO) is called a Core Interface (CIF).



Sales orders can be managed using the component SAP CRM, but can bemanaged in SAP ECC also.

Production TypesDepending on the manufacturing process, product complexity, stability ofproduction, and other criteria, a company has various requirements with regardto shop floor control.

For this reason, the SAP ERP and SAP SCM applications support a variety ofproduction types.

Figure 4: Production Types (1)



Figure 5: Production Types (2)



Lesson Summary

You should now be able to: you will be able to name the production types that are supported within the

SAP Business Suite.


Unit Summary SCM300

Unit SummaryYou should now be able to: you will be able to name the production types that are supported within the

SAP Business Suite.


SCM300 Test Your Knowledge

Test Your Knowledge

1. Name the production types that are supported within the SAP Business Suite.


Test Your Knowledge SCM300

Answers

1. Name the production types that are supported within the SAP Business Suite.

Answer:

Order-related production with production order Order-related production with process order Repetitive manufacturing:

Period and quantity-oriented production Not order-related

Kanban:

Replenishment-controlled using stock transfer, externalprocurement, in-house production via self-controlled control cycle

Project-oriented production with production lot


Unit 2Order-Controlled Production with

Production Orders

Unit OverviewIn this unit, you learn about order-controlled production with production orders.


Explain the characteristics of order-based production with production orders Describe the main steps for managing production orders Assess the main functions for managing production orders

Unit ContentsLesson: Order-Controlled Production with Production Orders... . . . . . . . . . . 12Lesson: Elements, Functions, and Processing of a Production Order.. . . 22

Exercise 1: Integration with Planning; Order Creation with PlannedOrders, Order Structure.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Exercise 2: Order Release and Order Processing ... . . . . . . . . . . . . . . . . . . . 61


Unit 2: Order-Controlled Production with Production Orders SCM300

Lesson: Order-Controlled Production with ProductionOrders

Lesson OverviewThe following topics are covered in this lesson:

Application areas of production orders Order-Based Production: Characteristics Cross-application functional process Master data for production orders


Explain the characteristics of order-based production with production orders

Business ExampleYour company manufactures some kind of order-related product. You belong tothe team that is implementing production orders in PPS. To do this, you mustimplement the whole process chain for in-house production, which will allow yourcompany to organize, control, and execute production for a plant based on theproduction planning and production control solutions.


SCM300 Lesson: Order-Controlled Production with Production Orders

Application Areas of Production Orders

Figure 6: Application Areas of Production Orders

Production orders are used in a variety of industries and industry sectors.

Production orders can be used in a number of production types.

These production types are mainly dependent on the product stability, productcomplexity, and the production procedures used.



Characteristics

Figure 7: Order-Based Production: Characteristics (1)

Figure 8: Document Type, Order Category, Order Type

In the SAP system, you use the document type to distinguish between businesstransactions.

Orders are one type of business transactions.



The order category is used to distinguish between the various orders that are usedin the different applications.

The client-specific order category definitions for each application cannot bechanged.

Within an application, users can define order types for an order category.

The order type controls various processes and functions:

Number assignment Setting default values User-defined status management User-defined field control (not for production orders in Release ECC 6.0). Control of special functions (activating BDE, QM, LIS and so on)

You make all necessary settings in Customizing.


A number of functions are available for production orders, which allow forcomplex support of production (see following slides).

The course SCM310 covers a selection of the most important functions in detail.




The PP-PDC (Plant Data Collection) interface is a widespread interface speciallydesigned for production orders, whose contents focus on data exchange betweenthe SAP ECC system and standard plant data collection systems (PDC).

Execution Steps (XSteps) are used for the variable description of processinstructions and messages in the production order. They form the basis onwhich data can be exchanged with the process control level (downloading controlinstructions and uploading process messages) and interactive work instructionsgenerated for the machine operator.

SAP ODA (Online Data Access) supports data exchange between SAP ECCand process control systems of different manufacturers in the area of industrialproduction and is based on the Standard OPC Open Connectivity in industrialautomation:

This is a manufacturer-independent standard interface for systems in theproduction area, which is used mainly in process automation.

The task of an OPC server is to supply OPC clients (for example, the SAPECC system) with data from a wide variety of systems installed at the processlevel. Typical examples include: PLC (Programmable Logic Controller),SCADA (Acronym for Supervisory Control and Data Acquisition), DCS(Distributed Control System), HMI (Human- Machine Interface)

You can learn more about OPC under: http://www.opcfoundation.org/

SAP MII (Manufacturing Integration & Intelligence) is an independent SAPsoftware component and enables real-time data integration in ManufacturingExecution Systems (MES) by means of standardized, preconfigured connectors.



Cross-Application Functional Process

Figure 11: Cross-Application Functional Process

Production order management is a central part of a complex process chainstarting with an independent requirement (planned or customer requirement)and ending with the goods issue of a finished product.

Production order management controls the whole process of in-house productionof products and is integrated in the functions of capacity requirements planning,costing, and inventory management. Furthermore, there are links and interfacesto Quality Management as well as external systems.

The production order management uses the following system elements:

ALE, Workflow, Customizing, text processing, factory calendar, classification,communication, and graphics.



Master Data for Production Orders

Figure 12: Master Data for Production Orders

The material to be produced must have the procurement type in-houseproduction (X,E).

The BOMs are single-level BOMs. A special selection procedure chooses thevalid BOM.

The routings are normal routings. A special selection procedure chooses thevalid routing.

Work centers are assigned to operations in the routing.

Production resources/tools are assigned to operations in the routing.

Documents (managed in the document management system) can be linked withand displayed in the production order.



Demo Scenario: Pump Production in Plant 1000

Figure 13: Demo Scenario: Pump Production in Plant 1000

Demonstration of production with production orders:

Pumps and their assemblies (casing, shafts and so on) are manufactured in plant1000. The final and pre-assembly as well as assembly production take place in thewarehouse and partially as make-to-order production. Production is organized onthe basis of the workshop principle. The individual parts for assembly productionare transferred from the material stock to production by picking or using a pulllist. When the assembly is confirmed, the assembly stock receipt is posted directlyto the storage location that is assigned to the final assembly production line.Components for final assembly that are not produced at the assembly productionlines are transferred from material stock via the pull list.

The most important data in the training system is:

Material numbersR-F1## Pump (Make-to-stock and make-to-order

production)R-B1## Casing (Make-to-stock production)



Material numbersR-B2## Warehouse (Make-to-stock production)R-B3## Shaft (Make-to-stock and make-to-order

production)R-B4## Electronics (Make-to-stock production with production

version)

Work centersR-V## Pre-assembly 1R-M## Pre-assembly 2R-E## Final assembly 1R-L## Paint shopR-F## Final assembly 2R-P## Check



Lesson Summary

You should now be able to: Explain the characteristics of order-based production with production orders



Lesson: Elements, Functions, and Processing of aProduction Order

Lesson OverviewIn this lesson, you learn about important elements and functions of a productionorder as well as the typical way it is processed.


Describe the main steps for managing production orders Assess the main functions for managing production orders

Business ExampleImportant steps for order-related production are order creation, scheduling,release, printing papers, material withdrawal, execution, confirmation, goodsreceipt, and settlement. These functions are integrated with other areas in yourcompany, such as, controlling and warehouse management. For this reason, youmust take into account the extensive integration relationships of production ordersduring implementation.


SCM300 Lesson: Elements, Functions, and Processing of a Production Order

Production Order Processing and Structure

Figure 14: Production Order Processing

The production order goes through many individual activities.

Many of these activities can run automatically or in the background so thatmanual processing of orders is minimized.

A number of settings available in Customizing allow you to successfully performeach step in order processing.

(1) These functions can be automated via Customizing.

(2) These functions can be executed via background processing.

WIP determination, variance calculation, and settlement are generallyperiodic work for Cost Object Controlling (COC), and are usually processedin the background.

You can use the quality management (QM) tools during the production processand for the goods receipt.

Various interfaces for process integration are available for downloading ordersand uploading process messages.



Figure 15: Elements of a Production Order

A production order in SAP ECC has the mapped order structure.

A standard sequence of operations may have other (parallel, alternative)operation sequences.

You can make a selection from several alternative sequences.

The standard sequence must have at least one operation. If necessary, the systemcreates one automatically.

You can choose whether to assign material components, productionresources/tools and trigger points to the operation.

Suboperations are permitted within an operation.

You can link documents of the DMS (drawings, text files, images and so on) tothe production order (as of Release 4.6).

Execution steps are any process instructions (pressure, temperature, texts)that can be transferred to a recipient of your choice (control instruction in SAPECC, process control computer, CNC maschine) using the process integrationfunctions in the form of a control instruction or that can be prepared by thisrecipient and sent back to the SAP ECC system in the form of process messages(as of Release 6.0 EhP3).

Costs are determined at operation level, managed at order header level and asettlement rule is created for the orders for order-related COC only (optionalas of release 4.5).



Order Creation Options

Figure 16: Order Creation Options

Operations, material components and PRTs are usually taken from the routingand the BOM.

When opening a production order (and when creating a planned order), thesystem uses the criteria validity period and lot-size area to determine a suitableproduction version or direct routing/BOM alternatives for the material.

You can use production versions when opening production orders. A productionversion determines which routing alternative is to be used along with which BOMalternative for production.

When creating a production order without a planned order, the routing and BOMare copied directly to the production order.

When converting a planned order, the system does not read the BOM again.Instead, the dependent requirements in the planned order are converted intoreservations for the production order. In this process, any existing productionversion is also copied to the production order and the corresponding routingcopied.

You can create a production order manually any way you want.

If not otherwise specified in the routing, the components of the BOM areassigned to the first operation.



Integration with Planning (ECC or SCM (APO))

Figure 17: Integration with Planning (ECC or SCM (APO))

The ERP and SCM components offer two solutions for integrating planningand production:

Planning with the functions belonging to the SAP SCM (APO) component Planning with the functions of the SAP ECC component

The production preparation, execution, and control always occurs with thefunctions of the component ECC, but dependent on the production type.These functions include costing, release, material staging, confirmation, goodsmovements, and settlement.

Other functions (scheduling or the availability check, for example) can be carriedout using either of the SAP components. The master data and transaction data(planned orders, production orders, purchase requisitions, purchase orders, stocksand so on) are usually transferred between both SAP components via the interfaceCore Interface (CIF).

Specific events lead to the transfer of data from ECC to APO (release,confirmation, goods receipt) and vice versa.

Sales orders are usually entered in ECC and then transferred to SCM (APO).



Planned orders can be generated by material requirements planning in ECC(MRP) or with the following components in SCM:

Supply Network Planning in SAP APO (SNP)

This component achieves cross-plant planning in a long-term planninghorizon across the whole supply and procurement chain. Stock transportrequisitions (distribution), planned orders (in-house production), andpurchase requisitions (external procurement) are generated for eachproduction plant.

Production Planning and Detailed Scheduling in SAP APO (PP/DS)

This creates planned orders and purchase requisitions in a defined,short-term period (production horizon) in the production plant.

The SCM210 course covers the Core Interface (CIF) in detail.

The SCM220 courses up to SCM250 and SCM360 cover the planning tools indetail.

Order Creation with Planned Orders

Figure 18: Order Creation with Planned Orders

Planned orders are created using material requirements planning (ECC -MRP) or using planning in SCM (APO PP/DS or APO - SNP).

The creation of production orders using planned orders is the most importantapplication form in the whole PP application.



The production order data is created automatically in this way.

Inspection data is copied from the routing when an inspection lot is generated,but is not written in the production order.

The conversion of the planned orders created in production planning intoproduction orders (and the purchase requests into purchase orders) can be carriedout by the MRP controllers (purchasers) depending on the execution of productionplanning both in the SAP ECC system and in SAP SCM (APO).

Order Release Functions

Figure 19: Order Release Functions

The order release is the basis for the processes that follow the production order(printing order documents, material withdrawal, and so on).

Production orders are managed using statuses.

When an order is released, a status is set accordingly.

An availability check can be executed automatically.

You can release an individual operation, a whole order or several orders together.

A corresponding function is also available for the mass release of operations ororders (see the Mass Processing section).



Detailed Scheduling (Work Center Scheduling)

Figure 20: Detailed Scheduling (Work Center Scheduling)

Detailed planning (work center processing) can be carried out both in ECC(capacity planning) and in SCM (APO).

A prerequisite for all methods of detailed scheduling is long-term ormedium-term capacity requirements planning.

You can use the order information system to create a list of the operations foreach work center.

To do this, you must develop a special layout.

The courses SCM250 (APO) and SCM360 (ECC) cover capacity requirementsplanning in detail.



Example: Graphical planning table (APO)

Figure 21: Example: Graphical planning table (APO)

The screen shows an example of a graphical detailed scheduling planningboard in the SAP SCM (APO) system. A planning board like this is also availablein the SAP ECC (PP-CRP) system.

These planning boards are used for active influencing (capacity levelingmeasures) in an existing planning situation.

The planning boards may vary considerably (they may be customized) in bothsystems and may contain up to eight horizontal areas.

You can use these areas to display the utilization of work centers (capacities), theorder due list, the planned operations, the material stock development etc.

A second basic display method uses tabular capacity planning tables that enableyou to view the utilization of work centers in figures.



Availability Checks (Material, Capacity, PRT)

Figure 22: Availability Checks (Material, Capacity, PRT)

Production orders can be checked for material (components), capacity or PRTavailability. This can be done manually or automatically, individually or usingmass processing.

Check instructions control the availability check.

Inspection results

Assigning the confirmed quantity

(Partial quantities can be confirmed)

Status material shortage, capacity shortage, PRT shortage Missing part record

Depending on how it is controlled, the check is performed in the SAP ECCor SCM (APO) component.



Shop Floor Papers (Standard List Types)

Figure 23: Shop Floor Papers (Standard List Types)

The standard system provides various lists. These lists are compiled bylist-specific reports.

The user can generate additional lists.

For each order, a maximum of 20 lists may be called.

You use the document distribution to plot document originals.



Material Staging Process

Figure 24: Material Staging Process

The basis for material withdrawal for production orders may be materialwithdrawal slips, pull lists, pick lists, work instructions, weighing systems (basicexecution steps) connected using the interface PI-PCS or similar documents ortechniques.

To organize the material staging, the SAP ECC and SAP SCM systems providethe following different procedures that depend on the type of inventorymanagement and warehousing:

1. Warehouse management with the MM-IM (Inventory Management)component

2. Replenishment control with the KANBAN component3. Storage bin management and replenishment control with a warehouse

management system based on the component LE-WM (SAP ECC) orEWM (SAP SCM).



For the material staging from a warehouse management system, there are threeoptions for the production order. These options are described here:

Pick parts are provided for the production order in exactly the samequantity as the requirements quantity. The staging of these parts for theproduction order may occur in a physical storage bin or a dynamic storagebin (production order). Typical examples are high value parts such as wavesand casings.

Crate parts are ordered manually when a crate is almost empty.

Typical examples are small parts in containers such as screws, nails, ....

Release order parts are ordered manually. The required quantity iscalculated using the target quantities of the components in the selectedreleased orders.

Typical examples are laminates, paints, ..

Production Order: Goods Issue Posting

Figure 25: Production Order: Goods Issue Posting

The goods issue posting (GI) is executed for consumption of a materialcomponent for a production order.



The following functions are executed when a goods receipt is posted:

Storage location-related update of stock and consumption fields Reduction of reservations (for planned withdrawal) Determination of actual costs (evaluation) and update of order Generation of material documents, accounting documents and cost

accounting documents The material document describes the goods movement from the materials

management (stock) point of view. The accounting document describes the goods movement from the financial

accounting point of view. The cost accounting documents are used for various cost analysis purposes. When you display the material document, you can branch to the other

documents. You can print a goods issue document.

The GI posting is controlled using a movement type (261), to which each postingrefers.

This can take place manually or automatically.

Confirmations

Figure 26: Confirmations Overview



Confirmations are an important basis for entering internal activities performedfor the order, for the progress check and subsequent capacity requirementsplanning.

For this reason, exact real-time confirmations are of particular importance.

A confirmation causes various additional functions to be executed (see above).

Confirmations are always executed in the SAP ECC component, but can beimplemented with various technical procedures.

The standard system provides a range of online transactions in SAP ECC (seethe next slide).

Users of the browser-based Enterprise Portal can carry out confirmations aspart of the role of a production scheduler.

Confirmations from PDC systems are possible using the PP-PDC interface(see previous unit).

Confirmations can be automatically generated and processed using automaticprocess messages which, in turn, are generated from work instructions, using thePI-PCS interface, or using SAP ODA (see previous unit).

Confirmations can be generated and updated via anMii server (see previousunit).

As of Release 4.6, custom-programmed confirmation interfaces and externalsystems can be linked to the SAP ECC system, using and adapting the followingBAPIs:

BAPI_PRODORDCONF_PDC_UPLOAD_TE (time-event confirmation) BAPI_PRODORDCONF_PDC_UPLOAD_TT (time-ticket confirmation)



Figure 27: Confirmations

There are various procedures for confirmations in SAP ECC. Each procedureimplements different requirements that a company may have. Depending onthe application, one or more procedure may be used. The procedures must beselected to suit the methods of organization within your company and the allowedworkload.

For the most part, the two main types are operation-related and order-relatedconfirmations. Order confirmation is a confirmation of the entire order at orderheader level. An operation confirmation allows you to confirm an order stepby step. For this type of confirmation, there are various procedures available.You can carry out a confirmation for an order only if no confirmations havealready been entered for the operations.

Each confirmation is entered with a status (partial confirmation, finalconfirmation, automatic final confirmation).



Effects of a Confirmation

Figure 28: Effects of a Confirmation

Once an order has been confirmed, follow-on functions are performed. Theconfirmed quantity, the status RCK and actual costs are written to theproduction order.

When an operation is confirmed, an automatic goods issue is posted on the basisof the quantity that has been assigned the material components (backflush). Thesematerial components must be prepared for backflush posting and also be providedfor use at the work center.

When you confirm the last operation that must be confirmed (or for the operationwhere this posting is defined in the control key), an automatic goods receiptis posted.

Capacity reduction is carried out either in proportion to the quantity oractivity.

If a scrap or rework quantity is confirmed, a quality notification can begenerated automatically (as of ECC 6.0 EhP3).



Process Integration

Figure 29: Process integration

The process integration forms the interface between PP-SFC and the systemsthat are involved in process control (process control computers, process controlsystems, CNC control and so on.). The flexible structure of process integrationenables the connection of fully automated, partially automated and manuallyoperated lines. Process integration consists of the following functions:

Bidirectional communication with standard plant data collection (PDC)systems via the interface Plant Data Collection (PP-PDC).

Communication with the process control level using the PI-PCS interface orusing work instructions (see also Unit 4 Process Orders):

Generating and sending control instructions with variable processinstructions from released production orders. These processinstructions provide a detailed definition of the process steps to beexecuted and the actual data to be confirmed (via process messages).

Formatting the control instructions in natural language in the formof work instructions and their manual processing by the machineoperator on screen.

Sending the control instructions to process control computers usingthe PI-PCS interface and processing them automatically.



Receiving, checking and sending manually or automatically entered processmessages with the actual data of the production process from the workinstructions or the process control system. The data is transferred from theexternal system using the PI-PCS interface too.

Reading and writing data points and events using the function SAP OPC DataAccess (SAP ODA) by means of the OPC server of the ECC system (readingand writing using work instructions or by means of the function AutomaticallyCreate Process Messages).

Further process integration options include using the application Mii and theRFID.

Production Order: Goods receipt posting

Figure 30: Production Order: Goods receipt posting

The goods receipt posting (GR) is executed for the stock receipt of a productproduced using a production order.



The following functions are executed when a goods receipt is posted:

Generation of material documents, accounting documents and costaccounting documents

The material document describes the goods movement from the materialsmanagement (stock) point of view.

The accounting document describes the goods movement from the financialaccounting point of view.

The cost accounting documents are used for various cost analysis purposes. When you display the material document, you can branch to the other

documents. You can print a goods receipt document. Update of the delivered quantity in an order Evaluation of the receipt Credit to order Update of plant activity

The GR posting is controlled using amovement type (101), to which each postingrefers.

This can take place manually or automatically.

Debiting and Crediting

Figure 31: Cost Debit/Credit (Order-Related COC)



The manner in which a production order is credited and debited depends on thevariant of cost object controlling (COC) selected in Controlling.

You can perform this as follows:

order-related product-related

Order settlement credits the order.

Settlement is usually periodic.

It is controlled using a settlement profile.

It makes sense to use the order-related COC if the following conditions exist:

Flexible production environment Flexible product range Cost management of individual production lots If cost controlling is required for each order High setup costs Manufacture of co-products

For in-house production of materials, it is generally best to use standard pricecontrol. For more information on cost object controlling, see course AC520.

Figure 32: Cost Debit/Credit (Product-Related Cost Object Controlling)

Settlement is period-oriented based on the costs of the product cost collector.



The order settlement for the individual production order does not apply here.In this case, the production order has no costs and no settlement rule.

It makes sense to use the product-related COC if the following conditions exist:

Make-to-stock production Repetitive, mass production Product cost by sales order only in the profitability analysis





Mass Processing (HVOM)

Figure 35: Mass Processing (HVOM)



Collective Orders

Figure 36: Collective Orders

Collective orders are the only option for multi-level management of productionorders and for the complete integration in all modules (SD, MM and so on) ofthe SAP ECC system. A separate subordinate order is created for each bill ofmaterial component whose material master has special procurement key 52(special procurement type direct production). Individual orders can be added ordeleted. You can make every component of an order into an order (whether it iswith or without special procurement key 52). Other useful special procurementtypes, for example, production in another plant, can be combined withdirect production (collective order).



Information Systems for Order Management

Figure 37: Information Systems for Order Management

There are flexible evaluation options and several information systems forproduction orders. You will find most of these evaluation options under: ECCLogistics Production Shop Floor Control Information System. Theydiffer in the way they use the order database (directly or indirectly) as well asin the results they can show.

Systems marked with (1) are layout-controlled (profile-controlled up to Release5.0). You set layouts in the respective application. You can use the EnterprisePortal for the role of a production scheduler to process and track productionorders and other objects (inspection lots, quality notifications, malfunction reports,and maintenance orders).

In addition to the above-mentioned evaluation options, there are

Capacity evaluations Event Manager (SCM) Alert Monitor (APO) Batch where-used list Evaluation of digital signatures and other lists.



Exercise 1: Integration with Planning;Order Creation with Planned Orders, OrderStructure

Exercise ObjectivesAfter completing this exercise, you will be able to: Perform the requirements planning Convert planned orders to production orders Use the structure and interface of the production order

Business ExampleYour company consistently uses material requirements planning based on SAPECC or SAP SCM (APO). As the production manager, MRP controller orproduction scheduler, you therefore create a large number of production ordersbased on planned orders generated by the automatic material requirementsplanning run.

List of abbreviations for menu paths:

ECC System SAP ECCSCM System SAP SCMLO LogisticsPP ProductionSFC Shop Floor ControlMM Materials ManagementSD Sales and Distribution

Exercise Data



Task 1:You generate planned orders based on planned independent requirements. Convertthese planned orders to production orders, then get familiar with the orderstructure.

1. Check the stock/requirement situation for the following materials in plant1000.

R-F1## Finished productsR-B3## Assembly

Write down the current available quantity quantity for MRP element Stock:R-F1## ______________________R-B3## ______________________

2. Enter a sales order in Sales and Distribution for product R-F1## with theorder quantity 1 piece.

Use the following requirements parameter:

Order type OR (standard order)Sales organization 1000Distribution channel 10 (End customer sales)Division 00 (Division-wide)Sales office 1000 (Frankfurt)Sold-to party 1000 (Becker Company, Berlin)Ship-to party 1000 (Becker Company, Berlin)PO number GR##_001Requested delivery date Current date + 1 month

Hint: If the system suggests a different delivery date, confirm thisby choosing Enter.

Save the sales order.

Write down the order number and item:

Order number ________________ Item _________

3. Perform multilevel single-item MRP for the product R-F1## in plant 1000.

Continued on next page



Use the following data:

Field EntryProcessing Key NETCH (Net change for the total horizon)Create purchaserequisition

3 (Planned Orders)

Delivery schedules 1 (No schedule lines)Create MRP list 1 (MRP list)Planning mode 1 (Adapt planning data (normal mode))Scheduling 2 (lead time scheduling)

Caution: Do not select any checkboxes in the Process controlparameters screen area.

4. Check the stock/requirements situation again for the materials R-F1## andR-B3##. What do you notice?

Task 2:Familiarize yourself with the structure of planned orders and convert the plannedorders to production orders (individual and collective conversion).

1. Examine the details for a planned order of material R-F1## by displaying theorder from the stock/requirements list.

Write down the number of this planned order:

____________________________

2. Choose the Header tab page and make a note of the planned dates.

Planned start date: ________________Planned finish date: ________________Planned opening date: ________________Availability date: ________________

Does the planned order have a production version?




3. Choose the Assignment tab page. Who is the production schedulerresponsible?

4. Display the material components (dependent requirements) of the plannedorder.

5. Convert the planned order with the total quantity to a production order of theorder type PP01. To do this, follow the menu path in Production Control.

Write down the number of the production order created:

____________________________

6. Is the converted planned order still in the stock/requirements list?

Hint: Planned orders can also be converted to production ordersfrom the stock/requirements list. To do this, select the planned orderwith or by double-clicking and then ProdOrd.

7. Check the Assignment tab page header in the production order generated.

Do you still see the reference to the planned order?

8. Convert several planned orders to production orders at the same time. Usecollective conversion to do this.

Select the planned orders to be converted with the following parameters:

Planning plant: 1000MRP controller 0##Material R-F1##Order type PP01

Limit the selection date (to one month before or one month after the currentdate).

Write down the numbers of the planned orders you converted:

Planned order number Production order number____________ ________________________ ________________________ ____________




Task 3:In one of the production orders you have generated, look at the individual datasegments, screens, and data fields in the following sequence.

Note down any questions you may have on the meaning of the data fields andask your instructor.

1. Order header screens

Choose the appropriate tab for the following screens:

General

Assignment

Goods receipt

Control

Dates/Quantities

Master Data

Long text

Also notice the settlement rule of the order.

2. Overview of operation sequences

3. Operation sequence details

4. Operation Overview

5. Screens of the Operation

Select the operation 0010.

6. Material components Overview

7. Screens of the material component

Select the component 0010. Display the General Data and the Long Text .

8. Production resource/tool overview for operation 0010

9. Screens of the PRT

Select the PRT 0010.

10. Document overview

11. Display the document info record.Continued on next page



12. Display the original document.

View both originals from the order's document overview.

13. Display the costs

Itemization (costs)Analysis (cost elements)Cost component split (cost components)



Solution 1: Integration with Planning;Order Creation with Planned Orders, OrderStructureTask 1:You generate planned orders based on planned independent requirements. Convertthese planned orders to production orders, then get familiar with the orderstructure.

1. Check the stock/requirement situation for the following materials in plant1000.

R-F1## Finished productsR-B3## Assembly

Write down the current available quantity quantity for MRP element Stock:

R-F1## ______________________

R-B3## ______________________

2. Enter a sales order in Sales and Distribution for product R-F1## with theorder quantity 1 piece.

Use the following requirements parameter:

Order type OR (standard order)Sales organization 1000Distribution channel 10 (End customer sales)Division 00 (Division-wide)Sales office 1000 (Frankfurt)Sold-to party 1000 (Becker Company, Berlin)Ship-to party 1000 (Becker Company, Berlin)PO number GR##_001Requested delivery date Current date + 1 month

Hint: If the system suggests a different delivery date, confirm thisby choosing Enter.

Save the sales order.




Write down the order number and item:

Order number ________________ Item _________

a) Menu path: ECC Logistics Sales and Distribution SalesOrder Create

b) The order number appears below in the status bar, once you have saved.

3. Perform multilevel single-item MRP for the product R-F1## in plant 1000.

Use the following data:

Field EntryProcessing Key NETCH (Net change for the total horizon)Create purchaserequisition

3 (Planned Orders)

Delivery schedules 1 (No schedule lines)Create MRP list 1 (MRP list)Planning mode 1 (Adapt planning data (normal mode))Scheduling 2 (lead time scheduling)

Caution: Do not select any checkboxes in the Process controlparameters screen area.

a) Menu path: ECC Logistics Production MRP PlanningMultilevel Single-Item Planning

b) To run the requirements planning, select Enter and confirm the entryparameters by selecting Enter again.

4. Check the stock/requirements situation again for the materials R-F1## andR-B3##. What do you notice?

Answer: Planned orders have been generated.

Task 2:Familiarize yourself with the structure of planned orders and convert the plannedorders to production orders (individual and collective conversion).

1. Examine the details for a planned order of material R-F1## by displaying theorder from the stock/requirements list.

Write down the number of this planned order:




____________________________

a) Choose Details of Element, or double-click on the order number, tocall the planned order and select Change Element.

2. Choose the Header tab page and make a note of the planned dates.

Planned start date: ________________Planned finish date: ________________Planned opening date: ________________Availability date: ________________

Does the planned order have a production version?

a) No, the planned order has no production version.

3. Choose the Assignment tab page. Who is the production schedulerresponsible?

a) Production scheduler 0##

4. Display the material components (dependent requirements) of the plannedorder.

a) Choose Components (quick-info Component Overview).

5. Convert the planned order with the total quantity to a production order of theorder type PP01. To do this, follow the menu path in Production Control.

Write down the number of the production order created:

____________________________

a) Menu path: ECC Logistics Production Shop Floor Control Order Create From Planned Order

b) Enter the planned order number and press Enter.

c) Save the production order.

6. Is the converted planned order still in the stock/requirements list?

Hint: Planned orders can also be converted to production ordersfrom the stock/requirements list. To do this, select the planned orderwith or by double-clicking and then ProdOrd.

a) No, this planned order no longer exists in the stock/requirements list.

7. Check the Assignment tab page header in the production order generated.




Do you still see the reference to the planned order?

a) Menu path: ECC Logistics Production Shop Floor ControlOrder Display

b) The planned order number is still visible.

8. Convert several planned orders to production orders at the same time. Usecollective conversion to do this.

Select the planned orders to be converted with the following parameters:

Planning plant: 1000MRP controller 0##Material R-F1##Order type PP01

Limit the selection date (to one month before or one month after the currentdate).

Write down the numbers of the planned orders you converted:

Planned order number Production order number____________ ________________________ ________________________ ____________

a) Menu path: ECC Logistics Production Shop Floor ControlOrder Create Collective Conversion of Planned Orders

b) Enter the selection parameters including the planned opening date.

c) Select Execute.

d) In the list screen of the planned orders, select the orders that are to beconverted and select the Convert pushbutton (short info PlannedOrder list Convert).

Hint: The Convert button is on the bottom left.




Task 3:In one of the production orders you have generated, look at the individual datasegments, screens, and data fields in the following sequence.

Note down any questions you may have on the meaning of the data fields andask your instructor.

1. Order header screens

Choose the appropriate tab for the following screens:

General

Assignment

Goods receipt

Control

Dates/Quantities

Master Data

Long text

Also notice the settlement rule of the order.

a) Menu path: ECC Logistics Production Shop Floor ControlOrder Change

Hint: If you are on a detail screen of the production order,choose (menu path Goto Header).

b) To call the settlement rule, choose Header Settlement rule.

2. Overview of operation sequences

a) Choose (menu path: Goto Overviews Sequence overview).

3. Operation sequence details

a) Select the sequence

b) Choose (menu path: Sequence Details).

4. Operation Overview

a) Choose (menu path: Goto Overviews Operations).




5. Screens of the Operation

Select the operation 0010.

a) In the operation overview, select the operation for item 0010.

b) Choose (Operation Operation Details).

c) Choose the appropriate tabs for the individual screens.

6. Material components Overview

a) Choose (menu path: Goto Overviews Components).

7. Screens of the material component

Select the component 0010. Display the General Data and the Long Text .

a) Select the component for item 0010.

b) Choose (menu path: Component Component Detail).

c) Choose the corresponding tab pages for the General Data and LongText screens.

8. Production resource/tool overview for operation 0010

a) Choose Goto Overviews Operations.

b) Select the operation for item 0010.

c) In the lower toolbar, select PRT (short info Operation PRT's).

9. Screens of the PRT

Select the PRT 0010.

a) Select the PRT for item 0010.

b) Choose (menu path: Production Resources/Tools DetailsProduction Resources/Tools).

c) Choose the corresponding tab pages for the General, Quantities, andDates screens.

10. Document overview

a) Choose (menu path: Goto Overviews Documents).

11. Display the document info record.

a) Select the first document.

b) Choose (menu path: Document Display document info record).

c) Choose the appropriate tabs for the individual screens.

12. Display the original document.




View both originals from the order's document overview.

a) Select the first document.

b) Choose (menu path: Document Display original document).

c) Select one of the bitmap files.

d) Select Continue.

e) Repeat steps c and d for the other bitmap file.

13. Display the costs

Itemization (costs)Analysis (cost elements)Cost component split (cost components)

a) From the header of the production order, choose Goto CostsItemization or Analysis or Cost comp. structure.



Exercise 2: Order Release and OrderProcessing

Exercise ObjectivesAfter completing this exercise, you will be able to: Perform the order release Print shop floor papers Perform the material staging Perform the material withdrawal Perform an operation confirmation Post the goods receipt (to stock) Check the order progress in the order information system

Business ExampleYour company uses production orders to control production. As the productionmanager or production supervisor, you are responsible for shop floor control and,as an employee in production, you work based on production orders. In thisexercise you will perform the whole management process for a production order.It starts with the release of production orders and ends with the goods receiptof the material produced. You will use the order information system to controlthis whole process.

Task 1:Perform collective production order release for all orders with your productionscheduler number.

Hint: Note the default release period.

1. Choose the Selection tab and enter the following parameters:

List Order HeadersLayout Standard layoutProduction plant 1000Order type PP01Production supervisor 0##System status REL Released and Exclude




2. Choose the Mass Processing - Release tab page and make the followingsettings:

Field SettingsFunction ReleaseExecute function Execute function

immediatelyRelease control order Order release

3. Select all production orders and start the release (mass processing).

4. Check the release log for any errors.

5. Check the status changes in one of the production orders.What is the new status?

Task 2:Print all the shop floor papers for all the released orders of your productionscheduler number.

Use mass processing to print the production orders.


List Order HeadersLayout Standard layoutProduction plant 1000Order type PP01Production supervisor 0##Selection profile status PP00008

2. Choose theMass Processing - Printing of Shop Floor Papers tab page andmake the following settings:




Field SettingsFunction Printing of shop floor

papers

Execute function Execute functionimmediately

Print mode Original print

3. Select all production orders and start printing (mass processing).

4. Check the print log for any errors.

5. Look at the printing results.

6. Check the status changes in one of the production orders.What is the new status?

Task 3:Perform material staging and the goods issue posting for all the released orders ofyour production scheduler number.

Create a pick list for staging the material components of the order in stock.

1. Select the orders with the following parameters:

Profiles 000002 (standard pick profile)Plant 1000Order type PP01Production supervisor 0##

2. Use the Pick function to post the goods issues and save the result.

Hint: If there is not enough stock to withdraw a material, usetransactionMB1C, movement type '561', to perform an other goodsreceipt for the material. Post a sufficient quantity.

Hint: To display errors in picking, choose Environment Errors.




3. Look at the update in an order (documented goods movements, withdrawalquantities, actual costs).

4. Check the status change in the production order.What is the new status?

Task 4:Choose one of the orders processed so far for material R-F1## to performconfirmations.

Order number: _________________________

1. Perform a final confirmation (quantity and time) for operation '0070'. Usethe operation-related confirmation for the progress confirmation.

Hint: This type of operation-related confirmation confirms alloperations automatically and by quantity.

2. Display the confirmations performed for the order.

3. Look at the update (actual quantities, status, costs) in the order (order header,operations).

4. Check the material stock for material 'R-F1##'.

Material stock: _____________________




5. Was the stock receipt posted automatically?

6. Is the order still in the stock/requirements list?

7. Check the status change in the production order.What is the new status?

Task 5:Post a goods receipt for the whole order quantity of a different production orderfor material R-F1##.

1. Go to the detail screen for the posting and check the data.

Hint: The movement type for the goods receipt from productioncan be found in the menu.

2. Generate the overview for the goods receipt posting.

3. Save the goods receipt and note the material document number.

____________________




4. Check the update of the delivered quantity in the order.What is the new status?

Task 6:Use the order information system to check the order progress of all theproduction orders for your production scheduler number.


List Order HeadersLayout /SCM310_001Production plant 1000Order type PP01Production Scheduler 0##

2. Are the orders that have already been delivered displayed?

3. Repeat the order information system call with the following additional listsin the selection screen. All other selection parameters remain the same.

List Documented Goods MovementsList OperationsList Object Overview

Hint: In the object overview, the system hides the layout fortechnical reasons and displays profile 00000000001X. In thelist generated, you can expand individual objects (operations,components) of an order.



Solution 2: Order Release and OrderProcessingTask 1:Perform collective production order release for all orders with your productionscheduler number.

Hint: Note the default release period.


List Order HeadersLayout Standard layoutProduction plant 1000Order type PP01Production supervisor 0##System status REL Released and Exclude

a) Menu path: ECC Logistics Production Shop Floor ControlControl Collective Release.

2. Choose the Mass Processing - Release tab page and make the followingsettings:

Field SettingsFunction ReleaseExecute function Execute function

immediatelyRelease control order Order release

a) No solution required.

3. Select all production orders and start the release (mass processing).

a) To begin the selection, choose .

b) Select all orders in the detail list.

c) To begin the release, choose (menu path: Mass ProcessingExecute).




4. Check the release log for any errors.

a) Choose Order (Menu path: Mass Processing Log of Last MP).

5. Check the status changes in one of the production orders.

What is the new status?

Answer: REL (released)

Task 2:Print all the shop floor papers for all the released orders of your productionscheduler number.

Use mass processing to print the production orders.


List Order HeadersLayout Standard layoutProduction plant 1000Order type PP01Production supervisor 0##Selection profile status PP00008

a) Menu path: ECC Logistics Production Shop Floor Control Control Print.

2. Choose theMass Processing - Printing of Shop Floor Papers tab page andmake the following settings:

Field SettingsFunction Printing of shop floor

papers

Execute function Execute functionimmediately

Print mode Original print

a)

Hint: The original print print function prints all the releasedoperations of the order that have not been printed.




3. Select all production orders and start printing (mass processing).

a) To begin the selection, choose .

b) Select all orders.

c) To start printing, choose (menu path: Mass Processing Execute).

4. Check the print log for any errors.

a) Choose order (menu path: Mass Processing Log of Last MP).

5. Look at the printing results.

a) Menu path: ECC System Services Output Control ortransaction SP01.

b) Use your user name and the current date to select.

c) Choose Selection Execute.

d) Select a spool order.

e) Select Display Content.

6. Check the status changes in one of the production orders.


Answer: PRT (printed)

Task 3:Perform material staging and the goods issue posting for all the released orders ofyour production scheduler number.

Create a pick list for staging the material components of the order in stock.


Profiles 000002 (standard pick profile)Plant 1000Order type PP01Production supervisor 0##

a) Menu path: ECC Logistics Production Shop Floor ControlGoods Movements Material Staging Pick.

b) Enter the selection parameters.

c) Select Execute.




2. Use the Pick function to post the goods issues and save the result.

Hint: If there is not enough stock to withdraw a material, usetransactionMB1C, movement type '561', to perform an other goodsreceipt for the material. Post a sufficient quantity.

Hint: To display errors in picking, choose Environment Errors.

a) Select all components in the list.

b) Choose Picking.

c) Select Save in the pick list.

3. Look at the update in an order (documented goods movements, withdrawalquantities, actual costs).

a) Choose Goto Documented Goods Movements

b) Choose Goto Costs Analysis

4. Check the status change in the production order.


Answer: GMPS (Goods movement posted)




Task 4:Choose one of the orders processed so far for material R-F1## to performconfirmations.

Order number: _________________________

1. Perform a final confirmation (quantity and time) for operation '0070'. Usethe operation-related confirmation for the progress confirmation.

Hint: This type of operation-related confirmation confirms alloperations automatically and by quantity.

a) Menu path: ECC Logistics Production Shop Floor ControlConfirmation Enter For Operation Progress Confirmation.

b) Enter the order number.

c) Press Enter.

d) Select operation 0070.

e) Choose Final Confirmation on the Quantity/Activities tab.

f) Choose Save.

2. Display the confirmations performed for the order.

a) Menu path: ECC Logistics Production Shop Floor ControlConfirmation Display.

b) Enter the order number.

c) Select an operation.

d) Choose Detail.

3. Look at the update (actual quantities, status, costs) in the order (order header,operations).

a)

4. Check the material stock for material 'R-F1##'.

Material stock: _____________________

a) Menu path: ECC Logistics Production Shop Floor ControlInformation System Stock Overview

5. Was the stock receipt posted automatically?

Answer: Yes.




6. Is the order still in the stock/requirements list?

Answer: No.

7. Check the status change in the production order.


Answer:CNF (confirmed)DLV (delivered)

Task 5:Post a goods receipt for the whole order quantity of a different production orderfor material R-F1##.

1. Go to the detail screen for the posting and check the data.

Hint: The movement type for the goods receipt from productioncan be found in the menu.

a) Menu path:ECC Logistics Production Shop Floor ControlGoods Movements Goods Receipt.

b) Enter movement type 101 and the order number.

c) Press Enter.

d) Choose Adopt + Details.

2. Generate the overview for the goods receipt posting.

a) Choose Copy.

3. Save the goods receipt and note the material document number.

____________________

a)

4. Check the update of the delivered quantity in the order.


Answer: DLV (delivered)

Task 6:Use the order information system to check the order progress of all theproduction orders for your production scheduler number.

1. Select the orders with the following parameters:Continued on next page



List Order HeadersLayout /SCM310_001Production plant 1000Order type PP01Production Scheduler 0##

a) Menu path: ECC Logistics Production Shop Floor ControlInformation System Order Information System.

b) Enter the selection parameters.

c) Select Execute.

2. Are the orders that have already been delivered displayed?

Answer: Yes.

3. Repeat the order information system call with the following additional listsin the selection screen. All other selection parameters remain the same.

List Documented Goods MovementsList OperationsList Object Overview

Hint: In the object overview, the system hides the layout fortechnical reasons and displays profile 00000000001X. In thelist generated, you can expand individual objects (operations,components) of an order.

a) Enter the selection parameters.

b) Select Execute.

c) When you have called the object overview, expand individual objects.



Lesson Summary

You should now be able to: Describe the main steps for managing production orders Assess the main functions for managing production orders


SCM300 Unit Summary

Unit SummaryYou should now be able to: Explain the characteristics of order-based production with production orders Describe the main steps for managing production orders Assess the main functions for managing production orders


Unit Summary SCM300



Test Your Knowledge

1. Name some application areas for production orders.

2. Name some basic functions of the production order.

3. Name the master data for the production order.

4. Name the main steps in the processing of a production order.


Test Your Knowledge SCM300

Answers

1. Name some application areas for production orders.

Answer:

Special production Make-to-order production Production by lot size Assembly processing/assemble-to-order Period-based production Mass production

2. Name some basic functions of the production order.

Answer:

Status management Scheduling Calculating capacity requirements Costing Availability checks (material, PRT, capacity) Printing shop floor papers Material staging using reservations Confirmation of quantities, activities, and time events (variable

confirmation procedure) Goods receipt Period-end closing (process cost allocation, overhead rates, WIP

calculation, variance calculation, order settlement) Archiving and retrieval Mass processing



3. Name the master data for the production order.

Answer:

Material BOM Work center Routing Production resources/tools Documents

4. Name the main steps in the processing of a production order.

Answer:

1. Order Request2. Order Creation3. Availability checks (can be automated)4. Scheduling5. Order release (can be automated)6. Download to BDE system7. Order printing (can be automated)8. Material staging9. Material consumption posting/withdrawal (can be automated)10. Upload from PDC system11. Confirmation (can be automated)12. WIP determination13. Goods receipt (can be automated)14. Variance calculation15. Order settlement16. Archiving/Deletion


Unit 3Order-Controlled Production with

Process Orders

Unit OverviewIn this unit, you learn about process-order-controlled production.


Explain the characteristics of order-controlled production with process orders Describe the individual steps in process order management Describe the concept of process management and use a PI sheet to execute

a process order Explain the special functions for process order management in the

pharmaceutical area

Unit ContentsLesson: Order-Controlled Production with Process Orders ... . . . . . . . . . . . . . 82Lesson: Elements, Functions, and Processing of a Process Order.. . . . . . 93

Exercise 3: Master Data for Order-Controlled Production with ProcessOrders .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115Exercise 4: Integration with Planning; Process Order Creation withPlanned Orders .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121Exercise 5: Process Order Release; Processing an Order with a PISheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133


Unit 3: Order-Controlled Production with Process Orders SCM300

Lesson: Order-Controlled Production with ProcessOrders

Lesson OverviewThe following topics are dealt with in this lesson:

Application areas of process orders Process Order-Controlled Production: Characteristics Cross-application functional process Master data for process orders


Explain the characteristics of order-controlled production with process orders

Business ExampleYour company is a process manufacturing company. You produce order-relatedproducts. You are on the project team for implementing shop floor controlfunctions based on process orders.

Application Areas of Process Orders

Figure 38: Application Areas of Process Orders


SCM300 Lesson: Order-Controlled Production with Process Orders

Process orders are used in different areas of the process manufacturing industry.

Process orders can be used for various production procedures and identified, forexample, according to the criteria product complexity and product stability.

Process Order-Controlled Production: Characteristics

Figure 39: Process Order-Controlled Production: Characteristics (1)

(*) Note:

In process manufacturing, there are usually increased requirements with regard tothe integration of batch management and quality management within the supplychain.


Unit 3: Order-Controlled Production with Process Orders SCM300


Notes:

The creation of process orders corresponds in many ways to the creation ofproduction orders. The following basic functions are also supported by productionorders, although they are usually used in process manufacturing:

(1) A production version must be selected for order creation.

(2) The materials in process manufacturing are typically managed in batches.There are functions for batch number assignment for the product and for batchdetermination of material components.

(3) After order release, control recipes with parameters for the process control levelcan be generated and sent to an external system or formatted within ECC in theform of a process instruction (PI) sheet to be processed interactively on the screen.

Hint: The synonymous terms control instruction (= control recipe) andwork instruction (= process instruction) are used for production orders.


SCM300 Lesson: Order-Controlled Production with Process Orders


Process Management

Process management is the interface between the process orders and the systemsinvolved in process control. Due to its flexible structure, it can be connected tofully automated, partially automated, and manually operated lines.. Processmanagement includes communication with the process control level using thePI-PCS interface or using PI sheets.

Control recipes are sent from released process orders to process control systemsor are formatted in nat