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SAP AG 1999

TAPP40 Production Planning - Part 2

SAP AG

TAPP40TAPP40

Production PlanningPart II

Production PlanningPart II

n System R/3

n Release 4.6B

n August, 2000

n Material Number: 50037270 Part 2 of 4

SAP AG 1999

Copyright 2000 SAP AG. All rights reserved.

Neither this training manual nor any part thereof maybe copied or reproduced in any form or by any means,or translated into another language, without the priorconsent of SAP AG. The information contained in thisdocument is subject to change and supplement without priornotice.

All rights reserved.

Copyright

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© SAP AG TAPP40 1-1

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Section: Basic Data


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Content: Basic Data (1)

Unit BOM Management

Unit BOM Reporting Functions

Unit Variants and Alternatives

Unit Material Master Records

Unit Configuring Material Master Records


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Content: Basic Data (2)

Unit Work Scheduling in Detail

Unit Scheduling

Unit Engineering Workbench

Unit Summary

Unit PP Organization Structures and Basic Data Overview

Unit Routing Part 1

Unit Work Center

Unit Routing Part 2


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l Organizational levels for the material master record

l Organization structures

l Material type - industry sector

l Views

l Number assignment

l Units of Measure

l Document Usage

l Material Status

l Deleting - Archiving

l Classification System

Contents:

Material Master


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At the conclusion of this unit, you will be able to:l Recognize the dependencies of the material

master record on organizational levels,material type, industry sector, and materialstatus.

l Set up the different options afforded bynumber assignment and units of measure.

l Create and maintain a material master.

l Archive and delete a material master.

l Use the classification system to find a materialnumber.

Material Master: Topic Objectives

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l A design engineer displays a material masterrecord.

l A finished product is created in the group andadded to the work views

Material Master: Business Scenario


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MaterialMaterial

l The material master contains information on the materials thata company constructs, procures, manufactures, stores, andsells.

l The information is stored in a database that is a central sourceof data on materials.

l The material master integrates data from different areas of acompany.

Material Master Definition

n For the company, the material master represents the central source for calling data on materials. The material master is used by various components in the SAP logistics system.

n The material can be a finished product (product, article), a semi-finished product (sub-assembly), or a raw material (purchased part).


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Controlling area1000

Controlling area1200

ClientClient

Plant 1000 Plant 1200Plant 1100 Plant 0001

Company code1000

Company code0001

Valuationarea 1000

Valuationarea 1100

Valuationarea 1200

Valuationarea 0001

Company code0002

Organizational Structures and Plants

n Organizational units are tightly linked to each other to quickly move the relevant data for a business function. For example:

� Plant 1000 is assigned to a company code 1000.

� Company code 1000 is assigned to a controlling area 1000.

� Therefore, whenever a transaction occurs in plant 1000 involving cost, the cost value is automatically updated via logical links to the appropriate cost management structure within controlling area 1000.

n The valuation area is the organizational level at which material quantities and values are managed. It is essential that for the product costing, a valuation area exists for each plant.

� Within a valuation level, you can differentiate between values and quantities (produced in-house versus externally procured) using different valuation types.

n In Customizing Materials Management MM, balance sheet valuation is specified either on a company code level or on a valuation area level.

� Selection of valuation area level automatically causes the creation of a valuation area for each plant.

� In order to use product and order costing functionality, it is absolutely essential that inventory be valued at the plant level.


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Definition of a Plant

l A plant is an organizational unit within a company.

l A plant is a place where valued goods and services are:

n Produced

n Stored

n Consumed

n Distributed

l A plant can be used to define a:

n Manufacturing facility

n Warehouse distribution center

n Corporate headquarters

n Sales office


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Valuation levelProduction levelEngineering/design level

Engineering/design level

Storage loc.0003(WMS warehse)

Plant 1200 Plant 1300

Storage location 0001

ClientClient

Storage location 0002

Organizational Levels in Logistics and PDM

n Organizational levels in the SAP System are:

� Structures that represent a legal or organizational view of a company.

n The organizational levels form a framework for supporting all business processes.

n The client is a complete technological, organizational unit within the SAP System that complies with commercial law. It has separate master records and its own record of tables.

n The plant is a place of work or a branch of a company.

n The storage location is an organizational unit that makes it possible to distinguish between material stocks within a plant.


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l The material master has ahierarchical structure whichcovers the followingorganizational levels:n Client, plant, storage location

l The hierarchical structuremakes it easier to organizeinformation on materials andminimizes data redundancy.

l Engineering/design data ismanaged mainly on a clientlevel.

Storagelocation

MaterialMaterial

Storage location-specific dataStorage location-specific data

Stock quantitiesStock quantities

ClientClient

Plant

General dataGeneral data

Plant-specific dataPlant-specific data

Material numberMaterial numberDescriptionDescriptionUnits of MeasureUnits of MeasureTechnical dataTechnical data

MRP dataMRP dataWork scheduling dataWork scheduling dataPurchasing dataPurchasing data

Organizational Levels for Material Master Record

















n Some material data is valid on all organizational levels and other data is only valid for specific levels. So that the material data can be managed centrally in the company without filling the datasets with unnecessary information, the material master has been structured hierarchically and in such a way that a company structure can be represented in it.

n Data on client level General material data that applies to the whole company is stored on client level. Examples of this kind of data are material short texts, base units of measure and conversion factors for alternative units of measure.

n Data on plant level All data that applies to a plant and its assigned storage locations is stored on plant level. Examples of this kind of data are MRP and forecast data.

n Data on storage location level All data that applies to a specific storage location is stored on storage location level. This is mainly storage location stock.


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Raw materials

Semi-finishedproducts

Finished products Finished products

Other Other

Mechanicalengineering

l Material master records aregrouped according to industrysector and material type.

l The industry sector determineswhich industry-specific dataappears in the material masterrecord.

l The material type determineswhich departments can enterdata and whether quantitiesand/or values are updated ininventory management.

Semi-finishedproducts

Chemicals

Raw materials

Industry Sector and Material Type

n During material master creation you must define the material's industry sector and material type.

n Industry sector determines which data fields and screens are available for entry during material master maintenance.

n Material type determines the allowed business processes (sales, production, purchasing, etc.) and functions (use material in BOM, routing) for a material.

n The person who creates the initial material master view defines:

� The material number

� The industry sector

� The material type

� The unit of measure, and

� The description

for the material.


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Material type

Material Type

l A material type groups togethermaterials that have attributes incommon.

l The material type controls:

n Which departments (views) areable to maintain material data

n Whether and how quantities andvalues are updated in thesystem

n Whether the material is procuredinternally or externally

n Which G/L accounts (forexample, material stock account)are updated

n So that you can manage different materials according to the company's requirements, materials with the same characteristics are divided into groups and assigned to a material type. Examples of material types are raw materials, semi-finished products, finished products and so on.

n When you create a material master record, the material type determines:

� Which departments can maintain the material master record

� Whether the material number is assigned internally or externally

� Which number range interval the material number comes from

� Which screens appear and in which sequence

� Which department-specific data you have to enter

� Whether quantity changes in the material master record are updated

� Whether value changes to financial accounting stock accounts are updated

n Additionally, the material type determines the procurement type of a material. For example, whether the material is produced in-house, procured externally, or both.

n Moreover, the material type also determines which accounts are posted when a material enters or leaves the warehouse.


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Material Master

Pump

Shaft

Gasket

DefinitionDefinition

ExamplesExamples

Business Processes Supported

Material Type Sales Purchasing Production

FINI

SEMI

RAW

Yes

No

No

No

No

Yes

Yes

Yes

No

The material master is a central data object in the SAP System. It is used to model raw materials, auxiliary materials, semi- finished products, products and production resources and tools


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Changing Material Type

l Since material type influences internal processing,system checks are performed before changes are allowed.

l You can change the material type without restriction if nostocks, reservations, or purchasing documents exist.

l If stock, reservations, or purchasing documents exist, thematerial type can be changed if:

n The same GL account is used as by the old material type.

n Quantities and values are updated as they were by the old materialtype.

n For further conditions refer to the documentation.


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Description of Industry Sector

Plant engineering/constructionChemical industryMechanical engineeringPharmaceuticals

Industry sector

B

AC

PM

l The industry sectordetermines, which branch ofindustry the material isassigned to.

l The industry sectordetermines:

n Which screens appear andin which order

n Which industry-specific dataappears

Industry sector

n Besides grouping together materials as different material types, you must also assign a material to a specific branch of industry. You can do this by specifying the industry sector when you create a material master record.

n If necessary, you can hide this field from display.


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t

AB B C

B

A BXX XX

Storage

Basic dataBasic data

MRP

Accounting

Warehouse management

Plant / storagelocation stock

Purchasing

Sales and Distribution

Workscheduling

Qualitymanagement

Forecasting

ClassificationClassification

Material Material mastermaster recordrecord

Costing

Material Master Views

n The material master record is used by all SAP logistics applications. It controls whether a material is purchased, manufactured or sold.

n Every business function can maintain one or more views of the material master .

n Since different user departments in a company work with the same material, and each of these departments wants to store different information on the material, you can subdivide material master data according to the department it "belongs" to. Each department has its own view of the material master record and is responsible for its data being correct.

n Data maintained in the following views is used by SAP's PP functions.

n The basic data view includes general data such as the material number, the material description, base unit of measure, and technical data.

n The classification view contains user-defined specifications for a material.

n The MRP view contains plant-specific data used in the planning of materials for production or procurement.

n The work scheduling view contains plant-specific data used in the scheduling of materials for production.


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Material Master: PP Data

Basic Data View

Material numberMulti-language descriptionsBase unit of measureCross-plant material statusSize, weight, and so on.Drawing dataIndicator: Configurable material

Classification View

Class type - 001 (Material)ClassCharacteristic value

MRP View

Procurement typePlanning procedure (MPS, MRP, other)Planning strategyLot size/safety stock rulesIndicator: BackflushingPlant-specific material statusMRP group and controllerAssembly/component scrapIn-house production timesIndicator: Repetitive manufacturing

Work Scheduling View

Issue/base unit of measureProduction schedulerIndicator: Batch mgmt. requirementDelivery tolerancesIn-house production timesQuality inspection indicatorDefault receipt/issue storage location

n Basic data view consists of common material information which can be used by all business functions and processes. The units of measure, dimensions, and configurable material indicator are used in BOMs and routings.

n Classification data is part of the general material data. The characteristic values are used to find a group of materials sharing an attribute.

n MRP data is plant-specific. The material status, backflush indicator, assembly scrap, and component scrap values are used in BOMs and routings.

n Work scheduling data is plant-specific. The issue/base units of measure are used in BOMs and routings.

n The lot size-dependent in-house production time in the work scheduling view can be updated from the material's routing data.


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Default valuesDefault values

Copy from materialCopy from material

Material Master Material Master record maintenancerecord maintenance

Maintenance Functions

n You can define defaults for views, organizational levels, and the industry sector. You can take the dialog boxes for selecting views and organizational levels out of the standard screen sequence. You can hide the industry sector.

n If you copy from another material, values from the material master are copied to the new material master record that you are creating, where you can overwrite them.


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l To access material master data efficiently, you may:

n Predefine the industry sector

n Predefine the selection of your material master views

n Predefine the selection of your organization levels

l To promote more efficient and accurate entry of MRP /forecast data you can predefine multiple MRP / forecastprofiles:

n Default values for MRP / forecast data fields

n Rules for MRP / forecast data field entry

Material Master Defaults

n The MRP profile allows users to set default values for MRP data fields while defining whether the value can be changed during material master maintenance.

n If a change is made to a default value in the MRP profile and the field can not be maintained during material master maintenance, the system will automatically change the field value in all material masters linked to that specific MRP profile.


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Screens for Maintaining a Material Master

Initia

l leve

l

Basic data MRP Sales Forecasting

Main w

orkin

g lev

el

Main w

orkin

g lev

el

Text

Addit

ional

data

level

A BX X XX

MaterialMaterial

Documentdata

Unit of measure

Administrativedata

Consumption

t

Purchasing Accounting

n There is a standard sequence for the screens on the main working level. You can interrupt this sequence at any point to go directly to any other screen.

n To see the screens on the additional data level use the Extras button.

n Using the appropriate buttons, you can also branch from the main working area to secondary screens: For example: Accounting 1

Previous period, previous year or standard cost estimate


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Group 01

Internal NA interval

External NA interval

Group nn

Internal NA interval

External NA interval

...

Mat. typeMat. type

MaterialMaterial

Check externally assigned numberCheck externally assigned number ??

Number Assignment (NA) for Materials

NA = Numberassignment

n Each material has a material number.

n You can assign a number externally or internally.

n If you assign a number externally, you enter the desired character string when you create a material master record.

n If you assign a number internally, you do not enter any material number when you create a material master record. Until you save the material master record, the system sets the material number "internal" in the appropriate field. When you save, the system automatically assigns the next available number.

n The type of number assignment allowed depends on the chosen material type and is defined in Customizing.

n First, you have to maintain the material number groups . You then assign the material types to the groups.

n You can assign an interval to only one group.

n You can change the number level of an interval manually.


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Material number:18 Characters

Material number:18 Characters

Material

Conversion

Input/output length

Leading zeros

Template

Storage form

Material Number Display

Database

n The data you enter for material number conversion determines the way material numbers are displayed in dialog functions and printouts only. This means that the information is stored in the database without a conversion character.

n Caution: The form in which the material number is displayed is effective for all clients.


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Base unit of measure: piece

4 16 72

Carton(Unit of issue)

Crate(Purchase order

quantity)

Palette(Sales unit of measure)

Units of Measure

Carton(Unit of issue)

Crate(Purchasing unit)

Palette(Sales unit of measure)

n In addition to the base unit of measure that the system uses for stock-keeping and to execute all its calculations, other departments can use their own units of measure. For example, purchasing can use another unit of measure to sales and distribution or to the warehouse.

n All units of measure in the SAP System, in addition to the base unit of measure, are grouped together under the title ‘Alternative units of measure ’. There are the following alternative units of measure:

� Base unit of measure:

Stock-keeping unit. All other units of measure that you use, are converted to the base unit of measure. If there is no standard formula for converting an alternative unit of measure to the base unit of measure, you must enter the conversion factor for the units of measure in the material master.

� Purchasing unit:

Unit of measure used for ordering the material. This is the default unit displayed in purchasing functions.

� Sales unit:

Unit of measure used for selling the material. This is the default unit displayed in the sales order. You can change this unit in the sales order.

� Unit of issue :

Unit of measure for issuing the material from stock. You use this unit for goods issue and stock movement functions.

n The engineering/design department usually uses the base unit of measure.


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Create material masterCreate material master

Create operation:

Conversion factors to base unit of measureare known

Base unit of measure

Enter group name

Alternative units

Conversion factorsto base unit of measure

Create units of measure groupCreate units of measure group

Grouping Units of Measure

n You can group together several units of measure in a unit of measure group. You can assign these units of measure to a material.

n For each unit of measure in the group, you can enter the conversion factor to the base unit of measure.

n You can maintain the unit of measure groups in Customizing for Materials Management master data.


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Documents contain information that is useful either for the person responsible or for transfer between systems

ExamplesExamples

UseUse

Materialmaster records

Bill of material

NC program Inspection instr. Brochure Drawing

Document Usage


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Application No Dialog Warning Error

ApplicationApplication ControlControl

PurchasingBOM headerBOM itemRoutingIndependent requirementsForecastingMRPProduction order headerProduction order itemQuality checkPRTPlant MaintenanceInventory

Material status fieldMaterial status field

Basicdata

PlantXXX

X

XX

XXX

X

XX

Material Status

n The material status allows you to control the usability of a material for business purposes.

n You define the material status in the material master record in accordance with the material, client and plant.

n You can limit the usability of a material in different ways:

� The material can be flagged for deletion.

� The material can be locked against certain business processes by the material status from the Materials Management/Production Planning and Control view.

n You can display whether a material is subject to restrictions, and what these restrictions are, with the status information function. You can call this function when you create, display, or change a material master record. Proceed as follows: From any detail screen, you can click on the I icon next to the material description.

n You can define the material status for all plants (basic data view), or separately for each plant (plant view).

n The cross-plant status is dominant.


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Material Status: Client <-> Plant

Example:

MaterialMaterial

Client

1000

1100

1200

=>

Material status field:Material status field: Result in BOM maintenance:Result in BOM maintenance:

W:W:Warning in BOM itemWarning in BOM item

Warning messageWarning messagein group BOMsin group BOMs

W:Warning in BOM item

Warning message

in plant BOMs=>

E:

Error in BOM item

Error message

in plant BOMs=>

N:

No message

Warning message

in plant BOMs=>

n The material status on client level overrides the plant-dependent material status.

n If, for example, you set a material status on client level that disallows BOM maintenance, you cannot maintain a plant BOM for this material, even if the material status on plant level allows BOM maintenance.


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Maint. status

From datePlant

Warehouse no.Material

Material typeIndustry sector

Selection screenSelection screen

TP - F112

Parameter

Extendable materialsExtendable materials

Status Material

D TP - F112MRP

E TP - F112Purchasing

O TP - F112Basic data

B TP - F112Accounting

Extending a Material

n This function allows you to extend the material master record by further views.

n The following questions can be answered:

� Which departments have to extend a material master record?

� Which material master records does a single department have to extend?

n Important maintenance statuses:

Department: Maint. status

Work scheduling A Accounting B MRP D Purchasing E Production resources/tools F Basic data K Costing G Classification C

n If additional views are added to the existing master record then you can also work with the function create material.


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MaterialMaterial

NumbersNumbersNumbersNumbers

In plantsIn plants

Of material typeOf material type

For userFor user

Materials List

n This function allows you to create materials lists according to specific, combinable selection criteria:

� List of material numbers

� List of all materials that have been created in a certain plant

� List of all materials of a certain material type

� List of all materials of a certain material group

� List of all materials that have been created by a specific user in a material master record.


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Client

Plant

Storagelocation

1. 1. Set deletion flagSet deletion flag

2. 2. ReorganizationReorganization

Deleting a Material

n You can delete materials by setting a deletion flag either in the material master record or by using a proposal list.

n The deletion flag can be planned for the future and must then be activated at the correct time.

n All flagged records are deleted by a reorganizational program run, as long as these are no longer to be used, for example, as a BOM header.

n Material master deletion consists of three steps: 1) The material master is flagged for deletion 2) The material master is selected for reorganization processing 3) Reorganization processing is executed System checks are performed during reorganization to ensure the material can be deleted and archived with no impact on other R/3 processes.


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Tables

DatabaseDatabase

DatabaseDatabase

1. Archive

2. Delete

Sequentialfile

Archiving a Material

n You can archive material master records.

n The data is stored in a sequential file (archive file).

n Archived data can be deleted from the database during each deletion program or reorganization.

n Archived material master records can be displayed, but they cannot be retrieved.

n Archiving and reorganization are handled in detail in the administration courses.


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Routingheaders

Work centers

PRTs

Documents

Classification

Materialmaster records

RoutingRoutingGroup Z 1

10 Plz:1310

20

30

Classification System

l User-defined order structurel User-defined characteristics for

object searchl Hierarchy, graphic

n The functions of the Classification System are:

� To find an appropriate object based on user-defined criteria

� To find similar objects based on user-defined criteria

� To establish that no appropriate objects exist (To fulfil these objectives, you need to organize your data efficiently).

n The SAP classification system is a tool for organizing your data that goes far beyond matchcodes and systematically structured number assignment.

n The four parts of the classification system are:

� Maintain Characteristics

� Class maintenance

� Classification (assignments)

� Object search

n Course LO985 contains more information on the SAP classification system.


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Object searchObject searchClassificationClassification

Delivery headOutputTurning speedMaterial

: 10.94 yd: 20 m/s: 1000: Gray iron

l Char. Value Assgmt

l AssignmentObject:Class:

TP - F100Pump

- Pump lift- Output- Turning speed- Material- Usage

Class: pump

l Find objects in class

l Find class

- Pump lift- Output- Turning speed- Material- Usage

- Color- Pump medium- Type- Driven by

Characteristics

Maintain CharacteristicsMaintain CharacteristicsMaterial numberPump liftOutputTurning speedMaterial

: T - F100: 10.94 yd: 20 m/s: 1000 /min: Gray iron

Attributes

Object maintenanceObject maintenance

Class maintenanceClass maintenance

Classification System Functions

n An object is a classifiable unit. Examples: material, supplier, work center, customer, and so on.

n A class is a description of a group of objects that have specifications that are common or similar.

n A characteristic describes specifications of an object. Example: length, width, weight, color, and so on..

n A characteristic value represents the exact specification value of a particular object.

n The procedure for class maintenance is as follows:

1. Step 1: Define characteristics and allowed characteristic values

2. Step 1: Maintain the class, including the assignment of characteristics

3. Step 1: Maintain the objects (for example, materials), including assigning them to one or more classes, and assigning values to them

4. Step 1: Search for objects


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PumpsPumpsList of materialsList of materials

List of classesList of classesOilPumpsTools

Display material master

Match-code KWhat is the number What is the number

of the material?of the material?

?

Material _____

Displaymaterialmaster

Material _P-105

P-103 10 SteelP-105 10 Steel

Delivery head 10 mTurning speed 1000Material Steel

Finding a Material

List of materials CharacteristicsCharacteristicsPumps

List of classesList of classes

n The classification system makes it easy for you to find objects (for example, materials).

n If you have set up a classification system, you can use it to find a material number and copy the number to your application at any point where you need to enter a material.


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Cur. chng = (0000 - 0100)

Display = (0000 - 5000)

Authorization: Data field: Data field:

Cur. ch

ngDisplay

Cur. chng

Material Material 47114711

Material Material 47124712

Material Master Material Master Authorization group:Authorization group: 150 150

Authorization Groups for the Material Master

Authorization group: 50

n Setting up user master records and authorizations is dealt with in a separate course on this subject.

n If you have the appropriate authorization, you can display and check authorization objects in Customizing.


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You are now able to:l Maintain different organizational levels for a material.

l Control the processing of materials by material type,industry sector, and material status.

l Carry out the number assignment internally or externally.

l Divide and maintain the material master record data intodifferent user departments (views).

l Use the Extend material function, which allows you tomaintain further views besides creating a material.

l Classify materials using the classification system, whichtherefore enables you to find the materials more quickly.

Material Master: Summary


Data Sheet for the Exercises Explanation of the Symbols used in the Exercises and Solutions

Exercises

Solutions

Course Objectives

Business scenario

Tips & Tricks

Warning or point of caution

Data in the Exercises

Type of Data Data in the Training System

T-F1## T-F1##

T-F##

T-GR##

T-B## T-B1##

100-100 100-100

100-110 100-110

100-120 100-120

100-130 100-130

100-200 100-200

100-300 100-300

100-600 100-600

100-700 100-700

100-800 100-800

T-B100 T-B100


T-B200 T-B200

T-B300 T-B300

T-T1## T-T1##

T-T2## T-T2##

T-F3## T-F3##

T-T0## T-T0##

T-T4## T-T4##

T-F1## DRW 000 00 T-F1## DRW 000 00

T-FY## T-FY##

T-FZ## T-FZ##

T-BZ## T-BZ##

T-F77## T-F77

Activity group SAP_CA_PDM_DESIGNER


Exercises

Unit: Material Master

Topic: Relationship within SAP PDM

At the conclusion of these exercises, you will be able to:

• Display a material master

A design engineer displays a material master record.

1-1 Display material master record T-F1## (##=group number).

1-1-1 Use the Defaults menu option to change the default settings for processing as follows:

Industry sector: Mechanical engineering Hide industry sector on initial screen

Views : Basic data 1 + 2 MRP 1 through 4

Organizational levels: Copy from:

Plant: 1000 1000 Storage location: 0002 0002

1-1-2 Write down the entries you see for:

Base unit of measure? ___________ Material group? ___________ Lab./ office ___________ What does the abbreviation ‘Lab./ office’ mean ? ___________ Procurement type ___________

1-1-3 Display a relevant original document from the material master record. (Enter the document type DRW if required).

1-1-4 When and by whom was the basic data view for the material master record created: (see icon i) By whom? ___________ When? ___________


Exercises


Topic: Maintaining Material Masters


• Create a material master record using a source document and classification.

• Enhance and classify a material master

A finished product is created in the group and added to the work views

1-2 Create the following material master record by copying from a reference material: A finished product (FERT) T-F## (## = group number) by using material T-F1## as the reference.

Create the following views: Basic data 1+2 MRP 1,2,3 and 4.

1-2-1 Enter material number T-F## and use T-F1## as the material to copy from.

1-2-2 Which views are selected? _______________________________________________________

You want to ensure that you are creating a material for plant 1000, storage location 0002. To do this, choose Organizational levels.

Add your group number to the description field.

Display and check all your chosen views before you save. Ignore any warnings.


1-3 Create another material master record as follows: A semi-finished product (HALB) T-B## by using material T-B1## in plant 1000 to copy from, and the following views: Basic data 1+2 MRP 1,2,3 and 4.

Change the descriptions to match your group number.

Make sure that you change the storage location to 0002 in the MRP view.

1-4 Delete the default value for the views that you created in the first exercise.

1-5 Create a third material master for the finished product T-GR## with the view Basic data 1: Description “Demo LO205 Group ##” Base unit of measure “PC”.

Save this material master record.

1-6 Extend this material master record using the function Extend material view(s). Use the selection criteria of Maintenance Status: MRP

Set the created on date from yesterday to tomorrow.

Select material master record T-GR##

Create the MRP views for plant 1000 and storage location 0002

Maintain all required fields with the selections of your choice.

Save the material master record

1-7 Now mark the material master record T-GR## for deletion.

1-8 Create a Classification view for the material master record T-F##.

Class type : 001 Material class Class: 100 Pumps Characteristics: Pump height (forderhohe): 10 m Pump capacity (forderleistung): 20 m³ Speed (drehzahl): 1000


Solutions


Topic: Relationship within SAP PDM

1-1 Material master display under:

Logistics → Production → Master data →Material Master→ Material → Display → Display current or Logistics → Central Functions → Engineering→ Material → Display → Display current or Logistics → Materials Management → Material Master→ Material → Display → Display current

1-1-1 Material: T-F##

Defaults → Industry sector

Industry sector:‘Mechanical Engineering’

Select ‘Hide industry sector on initial screen’

Select: Enter

Defaults → Views

Views: ‘Basic Data 1’ ‘Basic Data 2’ ‘MRP 1’ ‘MRP 2’ ‘MRP 3’ ‘MRP 4’

Select: Enter

Defaults → Organizational levels

Organizational levels:

Copy from:

Plant: ‘1000’ ‘1000’

Storage location ‘0001’ ‘0001’

Select: Enter


1-1-2 Basic Data 1 Tab

Base unit: PC Material group: 001 Lab./office: KB1 Description: ‘Construction office KB1’ MRP 2 Tab Procurement type: E (In-house)

1-1-3 Additional Data → Document data tab

Select and display a linked document (Document type DRW).

Mark the DRW document

Select Display

Mark each BMP file individually and view by selecting Enter

Close the drawing file.

1-1-4 Select: i button (information on material)

Basic Data view: Created by Bollinger 10/19/99


Solutions


Topic: Maintaining Material Masters

1-2 Material master creation

Logistics → Production → Master data → Material master → Material → Create (special) → Finished product or Create (general) → Immediately (Material type Finished product) or Logistics → Central Functions → Engineering→ Material → Material →Create (special) → Finished product or Create (general) → Immediately (Material type Finished product) or Logistics → Materials Management → Material Master→ Material → Create (special) → Finished product or Create (general) → Immediately (Material type Finished product)

1-2-2 Material: T-F##

1-2-3 Copy from Material: T-F1##

Views: ‘Basic Data 1’ ‘Basic Data 2’ ‘MRP 1’, ‘MRP 2’, ‘MRP 3’, ‘MRP 4’

Select; Enter

Choose Org. Levels: Ensure that plant 1000 + storage location 0002 are used for the copy from and to locations.

Ignore the warning message and view all of the chosen views, before you save.

1-3 Use the same procedure as for exercise 2-2. Exceptions: New material T-B## Material type Semi-finished product (HALB), reference material T-B1##.

Save when finished.


1-4 Delete the views portion of the Defaults selection that you made previously

Defaults → Views

Deselect Views: Basic Data 1 and 2

MRP 1, 2, 3, 4

Select: Enter

1-5 Use the same procedure as used for exercise 1-2-2. Exception: Material type FERT (finished product), without reference material. Make all required field settings. Use selections of your choice for each.

Save.

1-6 Logistics → Production → Master Data → Material Master → Other → Extend Material View(s)

Select and Execute the selection parameter maintenance status ‘D’, material T-GR## in the selection screen.

Select the line with the status “D” and execute Maintain material . Enter plant 1000, maintain the view with any values, and save.

1-7 Logistics → Production → Master Data → Material Master → Material → Flag for deletion → Immediately

Material T-GR##

Select: Enter

Mark material indicator

Save


1-8 Procedure as for 1-6, maintenance status ‘C’ or

Logistics → Production → Master Data → Material Master → Material → Create material (General) → Immediately

Material: T-F##

Select: Enter

Select: Classification

Select: Enter

Class type: 001 Material class

Select: Copy

Class: 100 Pumps

Select: Enter

Characteristics:

Pump height (forderhohe): 10m

Pump capacity (forderleistung): 20m³

Use (verwendung): Haus (house technology)

Select: Save


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l Material type

l Field selection

n Field selection group

n Influencing factors

n Link rules

l Customized material master

n Screen sequence

n Logical screens

n Screen modules

n Influencing factors

Contents:

Configuring Material Master Records


SAP AG 1999 SAP AG 1999

At the conclusion of this unit, you will be able to:l Enter the necessary Customizing steps for the

material master

l Create a material type

l Set the field selection

l Configure a user-specific material master

Configuring Material Masters: Topic Objectives


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l Your business requires a new material typebecause the current material type is notsufficient.

l You set up a new material type and a newmaterial status.

l Your business has its own design departmentand needs a user-defined material master recordfor its users.

Configuring Material Master Records: Business Scenario


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Check tables for material master

Configure customized material master

Screen sequence control / Field selection

Material Status

Material number

Set up material type

Configuration Sequence for Material Master

O

O

D

O

M

MaterialMaterial

n Legend:

R = Required activity (required)

O = Optional activity (optional)

D = Default available for activity (default)


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Field selection and screen sequence

General indicators (pricing for pipeline, process, configurable)

Costing control

Item category group in SD

Views for material maintenance

Procurement type

Type of inventory management (quantity/value)

Number assignment (check external numbers Yes/No)

Assignment of account categories and references

Authorization group

MaterialMaterial

Material typeMaterial type

Control Using Material Type

n You specify a material type for each material. The material type belongs to the general data of a material.

n The views specified for a material type determine the user departments that can be maintained for a material with this material type.

n You can control the type of inventory management (quantity and/or value) for a material type depending on the plant.

n Pricing can be defined as a default standard value or as a fixed standard value.

n The assignment of inventory and consumption accounts takes place using valuation classes.

n You can determine inconsistencies in valuation areas using Customizing for the material type.

n The material type has an influencing factor on field selection and the user-specific material master.

n You can control access protection more precisely using the authorization group.


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Test the link55

Change the field selection for this group in the control listassigned to corresponding list

Determine the field selection group to which the field belongs

Determine the corresponding control string

Determine the fields you have to change and the influencingfactor for each

44

33

22

11

Field Selection: Procedure

n There are 5 steps to setting the field selection:

1. Determining the influencing factor

2. Determining the control string

3. Determining the field selection group

4. Changing the control indicator for the field selection group in the corresponding control string

5. Testing the change

n You can find out the technical name of a field using Extended help .

n In Customizing, you can use the table name to help you find the appropriate field selection group.

n New in Release 4.6: The assignment of a table field to a field selection group and navigating between field selection groups, field options and the assigned control strings have been graphically formatted.


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Field Namee.g.: MARA-FERTH

Field Namee.g.: MARA-FORMT

Field Namee.g.: MARA-KZUMW

Hide

Display

Required

Optional

Field optionField option

1:nField selectiongroup

e.g.: 015

Applies to all fields in the field selection group

Field Selection: Field Selection Group

n One or more material master fields are assigned to a field group.

n The field option applies to all the fields in the field group (for example, all the fields are required fields).


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Plant

Industry sector

Transaction

Procurementindicator

Material type

é é é é3333

..................

..................

..................

?

Field selection

Field Selection: Influencing Factors

n A separate control string exists for each of these influencing factors.

n Each position in a control string of this kind applies to a specific field selection group. The field option applies to the entire field selection group and all the master data contained in it.


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Control list

Material type

Plant

Industry sector

Procurement indicator

Field reference Control list

E/F Control list



Transaction Field reference

Field Selection: List of Influencing Factors

n You generally use a reference key to specify which control list is valid for a factor.

n You can maintain the reference key for the material type , plant, and industry sector in the settings menu.

n Field references are assigned by SAP to the material master transactions and procurement types. In the settings menu, you can determine which group the individual fields are assigned to.


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++

+

+

+*

** * *

-

-

-

-

-

- - - -

*

*

.

..

Link rules

.

.

+

.

.

+

-

*

.

.

+

.

*

.

.

Material type

Plant

Industry sector

Transaction

Procurementindicator

Examples

+ - *

Field Selection: Link Rules

n Field selection in a material master transaction is generally determined by several control strings. The entries of all the control strings for the relevant operation are linked to one another.

n The link rules shown above determine which fields are selected for each group of material master fields. In order of priority, the signs mean:

- Hide

* Display

+ Required entry field for the item category

. Optional entry field for this item category


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l You can structure the material master according to thedemands of your company:

n You can remove screens, which are not required, from the screensequence.

n You can create your own screens, by adding or deleting screenmodules.

n You can influence individual fields in the screen modules.

ScreenScreenmodulesmodules

Basic data Basic dataSales

Purchasing

ScreensScreens ScreenScreensequencesequence

Customized Material Master

n Customized material master screens support efficient data maintenance by creating entry dialogs specific to your company's data requirements. The material master is a set of logical screens (views) organized in a specific sequence for easy access, when more than one view is selected. In the SAP System, this organization of logical screens is referred to as a screen sequence.

n Each logical screen consists of several programmed sets of material master fields. In the SAP System, these sets of material master fields are referred to as screen modules or subscreens. The fields assigned to each screen module can not be changed in Customizing.

n In Customizing material master, users can:

� Create/maintain screen sequences

� Create/maintain logical screens

� Maintain the order of logical screens in a screen sequence

� Maintain which screen modules appear on which logical screens

� Assign field selection influencing factors (material type, industry sector, etc.) to a screen sequence

� Assign a user or group of users to a screen sequence

� Preset the default organization level, default industry sector, and logical screens for a user or group of users.


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View: Basic data Log. main screen 7 Basic data

Additional screens e.g. short text,

units of measure...

Additional screens e.g. short text,units of measure...

User-Specific Material Master

n The views of the material master correspond to the logical screens in Customizing. The logical screen is the visible data screen.

n There are main screens (maximum of 29), additional screens (maximum of 15) and other screens (non-configurable, for example, initial screens).

n The additional screens are assigned to the main screen using function codes PBxx (this corresponds to the name of the pushbutton in the Screen Painter).

n The secondary screens can be copied to the additional data screens with automatic numbering (maximum of 15 additional screens incl. secondary screens).


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ForecastingForecasting

Work schedulingWork scheduling

MRP 2MRP 2

MRP 1MRP 1

ClassificationClassification


Sales and DistributionSales and Distribution

MRPMRP

PurchasingPurchasing

Work schedulingWork scheduling

ForecastingForecasting


SCREEN SEQUENCE 1 SCREEN SEQUENCE 2

Screen sequence

n A screen sequence consists of logical screens (views) and additional screens.

n The order of the screens can be specified for each screen sequence.

n You can define a screen sequence to meet your requirements and specifications.


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MRP 1

Scheduling

Lot size data

Procurement

1

8

2

MRP 2

Material number

Discontinued item

1

10

Forecast requirements

PlanningBOM explosion

MRP 2

Material number

Discontinued item

1

10

BOM explosion

Procurement

Screen Modules

n A logical screen (view) consists of several screen modules. It consists of a carrier screen where you can enter several screen modules (maximum of 6).

n Standard screen modules (SAPLMGDI) have exactly one frame that can contain up to 10 lines and they have exactly 83 columns .

n You are free to choose the sequence of the screen modules.

n You can vary the number of screen modules for each logical screen.

n Screen modules from different logical screens can be grouped together in one screen. The maintenance status of the screen module fields must be the same as the maintenance status of the logical screen. You may have to extend the status of the logical screen in Customizing.

n Changes to a logical screen are saved in the screen sequence that is changed. This means that if you change the structure of MRP 1 in sequence 99, this change is only effective in sequence 99.


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Influencing factors:

Screen ref. transaction 01 01

Screen ref. user TEMPLATE *

Screen ref. material type * *

Screen ref. indust. sector * *

Transaction(T130M in Customi-zing not maintainable)

Industry sector

Material type

Screen sequence 01 02

User

Influencing Factors for Screen Sequence

n You can create a screen reference for user, material type, and industry sector.

n This screen sequence becomes valid for the appropriate user, material types, and industry sectors by assigning the screen references to a screen sequence. In the above example, the screen sequence 01 would be valid for all users who are assigned to the 'Template' reference, irrespective of industry sector and material type.


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Summary: Customized Material Master

a) Use standard screen modules (recommendation)

b) Use field selection to show/hide fields fieldsc) Programming and integration of user-specific screen modulesd) Define the sequence of screen modules in the logical screen

Logicalscreen

Copy standard screen sequence "21"

Use your own name range for screen sequence => Y*, Z*

Delete, add to, or change logical screens in the new sequence

Define sequence of logical screens in screen sequence

Assign the new screen sequence to influencing factors

n When creating your own logical screens we recommend that you use the standard screen modules that are already available.

n You require your own screen modules, if different field groups or new fields are required.

n To create your own screen modules, copy the standard program SAPLMGD1 to its own function group (for instructions, see IMG). Then create the required screen module in the function group.

n Append structures have been defined in DDIC for including your own fields.

n You can only integrate fields from user-specific tables and user-specific carrier screens in the program SAPLMGMM by using modifications .

n You have to use IMG to create your own material master dialogs.


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Container requirements

Laboratories andoffices

Materialmaster record

Material groups

Temperatureconditions

Divisions(Areas of responsibility

in SD)

Storage conditions

Material

Other Check Tables for the Material Master

n The material master contains a series of fields that are checked against other tables. These tables must be set up before you create material master records.


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Configuring Material Master Records:

Unit Summary

You are now able to:

l Create and set up the material types that control thecentral processes for the material master.

l Configure the field selection specifically to yourcompany using field selection groups and controlstrings for the different influencing factors.

l Define the sequence and structure of the individualmaterial master views depending on the user,material type, and industry sector.


Exercises

Unit: Configuring Material Master Records

Topic: Configuring Material Master Records


• Create a new material type

• Set up a new field selection for your new material type and a new material status.

A new material type is needed in plant 1000. Since the old material number from the preceding system is very important, it should be a required entry in the SAP System. A new material status should only allow maintenance of BOMs with a warning message.

1-1 Add a new material type MA## (## = group number). As a template, use the material type for the finished product FERT. Replace FERT with MA00. Change the description of a new material to: GROUP ## Save the newly created material type before processing further.

Note the following specifications for the new material type: External and internal purchase orders are allowed. Externally assigned material numbers should not be checked against a number range. Product costing with quantity structure (BOM, routing) is not allowed.

For materials of this material type, the following views are allowed to be maintained: Work scheduling, classification, MRP, basic data, warehouse, plant and storage location stock, costing.

In all plants (valuation areas) the quantities and values for materials of this material type should be updated.

The valuation of all materials of this material type should be mandatory (that means not changeable) according to the valuation procedure moving average cost.

According to the account category reference 0009, the account assignment should take place parallel to the material type FERT.

1-2 Make sure that the number assignment for materials of your material type MA## is carried out from the same number range group as for standard material type FERT.


1-3 The material type MA## is used for the finished products that are copied from the external system. The following material master fields should be a required entry for material type MA##: Old material number (MARA-BISMT) Material status (cross-plant) (MARA-MSTAE)

1-3-1 To which field selection group do these fields belong? ______

1-3-2 When you create using the copy function, is the contents of the fields copied?__________

1-3-3 What other fields belong to these groups? __________ __________

1-4 Copy the field selection reference Z## and at the same time, configure the fields mentioned above as required entries. As a template, use the field selection reference for the finished product FERT.

Now assign the field selection reference Z## to your material type MA##.

Test your setting by creating a material T-A## with material type MA## (basic data 1+2 views only). The old material number for this material is undefined. Use your 'created material status' (if the optional tasks were carried out) for the valid-from date <today>.

OPTIONAL

1-5 Create a material status (Group## + 10, description: “Group ##”) that only allows the processing of BOMs with a warning.

Create another session and assign this status cross-plant to your material T-F##.


Exercises


Topic: Customized Material Master


• Create a user-specific material master

The material master should have a structure for individual users that is different to the delivery standard.

1-5 Set up a user-specific screen sequence ## (group number + 30) for maintaining material masters. Use screen sequence 21 "Std ind. (short) tab pages" as a template for your screen sequence ## ‘screen sequence group.##’.

1-5-1 You should delete the screen module environment (2010) from the logical screen 08 (basic data 2).

1-5-2 The logical screen 29 (MRP 4) should be adjusted. Simulate the screen first, and then delete all screen modules except:

1005 Material number 2502 Repetitive manufacturing control data 2504 Discontinuation control.

You should copy the screen module procurement (2484) from the logical screen 27 (MRP 2). Simulate your changes.

1-5-3 Delete the logical screen 27 (MRP 2) from your screen sequence.

1-5-4 Control your screen sequence ## so that the logical screens exist in the following sequence :

Screen 1 Basic data Screen 2 MRP 4 Screen 3 Work scheduling Screen 4 Storage Screen 5 Classification

The rest of the sequence following these screens should remain unchanged.


1-5-5 The screen sequence should be effective for your user LO205-##. Define a screen reference for your user and determine a new list of influencing factors .

1-5-6 Check your settings when you display material master T-F##.


Solutions


Topic: Configuring Material Master Records

1-1 Creating a new material type

Tools → Accelerated SAP → Customizing → Edit project SAP reference IMG button: Logistics general → Material master → Basic settings → Material types → Define attributes of material types:

Select: Fert – finished product – Copy as button

1-2 For the number assignment:

Tools → Accelerated SAP → Customizing → Edit project SAP reference IMG button: Logistics general → Material master → Basic settings → Material types → Define number ranges for each material type

Select material type Ma##, choose the group, to which the material type FERT belongs, and select Element / Group.

1-3 You can see the data for the individual fields that you want to change using the help field, and clicking on Technical Info. Setting the required entry: First you determine the numbers of the field selection groups.

Tools → Accelerated SAP → Customizing → Edit project SAP reference IMG button: Logistics general → Material master → Field selection → Assign fields to field selection groups

1-3-1 Field selection groups

MARA-BISMT: 11 MARA-MSTAE: 155

1-3-2 The contents of the fields is copied during creation, because the reference indicator is set.

Select the field and click on Detail or double click on the Field description.


1-3-3 Display the field selection maintenance in a field group maintenance.

Tools → Accelerated SAP → Customizing → Edit project SAP reference IMG button: Logistics general → Material master → Field selection → Assign fields to field selection groups

Find the fields in the table Field groups: MARA-BISMT: 11 MARA-MSTAE: 155 and click on the icon Field selection maintenance. No other fields belong to the field selection group 11. The field MARA-MSTDE belongs to group 155.

Copy a field selection reference with the new description Z## and set it up so that the fields named above are displayed as required entries. As a template, use the field selection reference for the finished product FERT. Select the line FERT and copy it into Z## (Edit → Copy as). Call up field groups 11 and 155 in the copied field selection reference Z##. Change the field option for the required entry.

Assign the field selection reference Z## to the material type MA##, whilst you assign the field selection Z## to the material type.

Logistics general → Material master → Basic settings → Material types → Define attributes of material types: Change button

Field reference now “Z##” instead of “FERT”.

1-4 Create a material status.

Logistics general → Material master → Settings for key fields → Define material statuses: Edit → new entries or existing material status Copy as button

In the BOM item area enter the identifier “A” (Warning).

Assign the status to material T-F## in the basic data 1 view.

Logistics → Production → Master data → Material Master → Material →Change → Immediately


Solutions


Topic: Customized Material Master

1-5 Copy screen sequence 21.

IMG → Logistics general → Material master → Configuring material master → Define structure of the data screens for each screen sequence

Choose screen sequence 21

Select the COPY AS button

Overwrite 21 with Y# or Z# then ENTER

Save

1-5-1 Select your new screen sequence ## and, by double clicking on the data screens, go to the dialog structure. Select the data screen Basic data and activate the Subscreens by double clicking. Select the module 2010 and delete it (edit>delete). Return to the data screen view.

1-5-2 Now select the data screen MRP 4 and call up the Subscreens by double-clicking. Display the Subscreens by clicking on the button View data screen. Select and delete all the Subscreens, except 1005, 2502, 2504. Overwrite the first Subscreen 0001 with the one for "Procurement” 2484. Simulate the changed screen → View data screen. Save your changes.

1-5-3 Go back to the data screens view again, select the MRP 2 screen and delete it with all its dependent entries. Save.

1-5-4 IMG → Logistics – General → Material Master → Configuring the material master → Maintain the order of the main and additional screens. Select your screen sequence number and choose Icon Detail.

Change the rank as required. Basic Data → 1 MRP 4 → 2 Work scheduling → 3 Storage → 4 Classification → 5

Save.


1-5-5 IMG → Logistics general → Material master → Configuring the material master → Screen sequences for users / material types / transactions / assign industry sectors. Double click User screen reference. Choose New entries button. Create and maintain a new entry. Name: LO205-##, Sref user: Z#

Under Screen sequence control, create a new string (New entries).

ScrRef. Transact. → 01

ScrRef. User → The user ref. that you created before, (Z#)

ScrRef. Mat.type → *

ScrRef. Industry sector → *

Ssq→ The screen sequence number that you created (Y# or Z#)

Save your changes.


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l Terminology

l Effectivity

l Item categories

l Customizing

Contents:

BOM Management


SAP AG 1999

At the conclusion of this unit, you will be able to:

l Work with the basic BOM terminology

l Create BOMs on client and plant levels

l Understand and apply effectivity, BOM categoriesand BOM usage

l Work with the different item categories of a BOM

l Set BOM and item statuses so as to control the BOMin other application areas

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BOM Management: Topic Objectives


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l Your company works with a centralengineering/design department.

l You create group BOMs and assign them todifferent plants.

l You expand the BOMs with different itemcategories.

l You use classification for the material search.

BOM Management: Business Scenario


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A bill of material is a comprehensive, formally structured list of the components

that make up a product or assembly. The list contains a description and object

number for each component, together with the quantity and unit of measure.

Bill of materialBill of material

Definition of a BOM

n BOMs and routings contain important basic or master data for integrated materials management and production control. In the design department, new products are designed to be suitable for production, as well as for their intended function. In this product phase, drawings and a list of all the required parts, the bill of material (BOM), are produced.

n BOMs can be found in various forms wherever finished products or semi-finished products are produced from several component parts or materials. Depending on the industry sector, they may also be called:

� Recipe lists

� Ingredients lists


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Part 1

Part 2

Part 3

Part n

Item n

Item 2

Item 1

Bill of materialBill of materialSingle-level BOMSingle-level BOM

AssemblyAssembly

Component n

Component 3

Component 2

Component 1

Terminology

n Assembly:

An assembly means a group of components for a product that belong together for the purposes of manufacturing. The assembly can itself be used as a component in another assembly.

n Single-level BOM:

A single-level BOM can be used to represent all components in one or more assemblies.

n Component, part and item are synonymous terms.

n Phantom assembly:

A phantom assembly is a group of components that belong together for production purposes but are not actually assembled.


SAP AG 1999

Basic dataBasic data SDSD

Production

Plant MaintenancePlant Maintenance

Materials mgmt.Materials mgmt.

ControllingControlling

l Purchasing

l Storage location

l Product costingl Material

l Equipment

l Documents

l BOMs

l Routings

l Classes

l PRTs

l Work Centers

l Sales order

l MRP

l Planned orders

l Production orders

BOM Integration

l Preventive maint. plan

l Maintenance order

n Data that is saved in BOMs forms a significant basis for various areas within production planning.

n Engineering/design creates BOMs. You can create BOMs in the SAP System using a CAD program and a CAD interface.

n Material Requirements Planning explodes BOMs in order to determine economical order quantities for a particular point in time.

� In work scheduling, BOMs form the basis for the planning of operations and production control.

� Production order administration uses BOMs to plan the preparation of parts.

n The BOM is also used:

� In the sales order as an aid to entering data

� In reservation and goods issue as an aid to entering data

� In product costing to calculate the material usage costs related to the finished product

n The simultaneous use of BOM data in several branches of a company shows the great advantage of integrated modules that are linked in such a way that they facilitate a flow of data between various work areas and allow all the users to access the current values at any time.


SAP AG 1999

Document

Material BOM

Material

Sales order BOM WBS BOM

Document BOM. Equipment BOM Func. loc. BOM

BOM Categories

n BOM categories are used to identify a bill of materials use within the SAP System.

n Material BOMs are used in PP to represent the structure of products that are manufactured.

n Sales order BOMs are used in PP to represent the specific bill of material used to manufacture a product for a specific sales order.

n The WBS BOM helps to create components in the Project System.

n A document can consist of several documents, for example, a program, technical drawings, paper documents, and photographs. Document structures (BOMs) are used to combine multiple documents (drawings, photos, manuals, and so on) into a single information record. Each individual document is created and maintained through the SAP document management system or in BOM management.

n Equipment BOMs are used in plant maintenance to describe the structure of a piece of equipment and to assign spare parts to the piece of equipment for maintenance purposes.

n Functional location BOMs are used in plant maintenance to combine multiple documents (drawings, photos, manuals, etc.) into a single information record.


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Before Creating a BOM

l Does a material master exist for the BOM header?

l How is the BOM going to be used?

l Is this material type allowed in BOMs?

l What is the area of validity?

l When will the BOM become effective?

l Are change documents necessary?

l Is the material part of a BOM group?

l What is the BOM status?

l Have default values been defined?

n The questions listed above must be answered before creating a BOM in the SAP System.


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BOM Default Settings

l The following default values are defined inCustomizing:

n BOM base quantity

n BOM status

l The following default values can be defined by the user:

n Item increment

n Item category

n Material provision indicator

n Various BOM reporting options

n You can use default values to change the data entries effectively.

n Each user can also define their own default values to optimize or simplify data entry.


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Bill of Material

Material 1

ExampleExample

Material Quantity

100

10

1

Item

10

20

30

Material 2

Material 3

Unit

piece

grams

meter


SAP AG 1999


Location data

EngineeringEngineering

Technical data

ProductionProduction

Operations

CostingCosting

Price

Sales and DistributionSales and Distribution

Order quantity

Production order

Salesorder

MaterialMaterialBOMBOM

Use

n The usage allows you to create separate BOMs for the various areas within the company, for example, engineering or manufacturing.

� The engineering BOM combines all the components of the product from the point of view of engineering/design and contains all the technical data.

� The production BOM is set up from the manufacturing points of view. For the assembly, data relevant to the assembly procedure for example,is required.

� The costing BOM is the basis for the automatic calculation of the material costs of a product.

n Of course, you can also work with just one BOM for all areas by using the item status to cover all possible differences.

n When creating BOMs with different usages for one material, the system saves each BOM usage under its own BOM counter.

n BOM usage is taken into account when authorization groups are used to control which users may maintain a particular BOM.

n 2 special uses exist in the SAP R/3 System:

� Universal

� Empty


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Plant

1000

1100

1500

1600

Group BOM

Internal no. 4801

Internal no. 4801

Internal no. 4801

Reference

Reference

ReferenceReference

ReferenceReference

ReferenceReference

Effectivity Area 1

n To define the conditions under which a material BOM may be used by different areas of a company, you define an area of validity and a validity period.

n The effectivity area defines which plants can use a material BOM.

n You can extend the effectivity area by assigning the same BOM (same internal number) to an object in different plants. If you do this, you should be aware that there is still only one BOM, so any changes you may make will affect all plants.

n There must be a plant view for the BOM header and all the item materials in the plant that the BOM is to be assigned to.


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Plant

1000

1100

1500

1600

Group BOM

Internal no. 4801

Internal no. 5678Internal no. 5678

Internal no. 4801

Internal no. 4801

Reference

Reference

ReferenceReference

ReferenceReference

TemplateTemplate

Effectivity Area 2

n Material BOMs can be effective on different organizational levels:

n A material BOM can manage data that is directly relevant to production. This leads to the effectivity area for the plant. The plant is the place of work where all necessary work preparations are organized, for example :

� Planning material requirements and

� Creating routings

In this case, you create a plant-specific BOM.

n You can also create a group BOM. This is a BOM without reference to any plant. This would be sensible, for example, when the engineer/designer is maintaining a BOM in the engineering/design phase. The group BOM can be made effective for individual plants by assigning it to these plants.


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Plant

1000

1100

1500

1600

Internal no. 4321



Internal no. 1924

Effectivity Area 3

n Plant-specific BOMs are independent of each other and exist separately in the system. This means that if you make changes to a BOM in plant 1000, BOMs in plants 1100, 1500, and 1600 will not be affected.


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Effectivity Period

12

9

6

3

11 1

7 58 4

210

Valid from dateValid from date

12

9

6

3

11 1

7 58 4

210

Valid-to date Valid-to date

22

n The effectivity period is the time during which the BOM is valid. The period is bound by the following entries in the BOM header and in the BOM item:

� Valid from date When creating a BOM, this date specifies the point in time as of which the BOM header or BOM item is effective. If you create or change a BOM by entering a engineering change number, the system copies the valid-from date from the change master record.

� Valid-to date This date marks the end of the effectivity period for the BOM item. The system calculates this dynamically when using engineering change numbers. When replacing one component with another on a BOM using engineering change numbers, the valid-from date on the new component and valid-to date on the old component will be the same date. The system will make the change from the old to the new component effective at 0:00 hours on the effective date.

Note: The system assigns a default valid-to date of 12-31-9999.

n You can define a valid-from date for an entire BOM or for a BOM item.


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More Effectivity Types: Serial Number

BOM for the pump with serial number 1002BOM for the pump with serial number 1002

l Color

YellowRedRedBlue

Change 0Change 0

Change 1Change 1

Change 2Change 2

l Pump type

PistonRotaryFly wheel

Change 0Change 0

Change 2Change 2

Change 3Change 3

RedRedYellow

PistonFly wheel

Color

Pump type

Serial no. 1000 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010

RedRedRedRed RedRed Blue Blue

Rotary

Yellow Yellow Yellow Yellow

Fly wheel

Fly wheel

Fly wheel Rotary PistonPiston PistonPiston

n As of Release 4.0 there is a serial number effectivity.

� You can determine the effectivity of an assembly depending on the serial number of a specific finished product.

� You can determine the effectivity for the serial number of a specific finished product or for a range of serial numbers.

n If you want to determine effectivity using serial numbers , you must use engineering change management.


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More Effectivity Types: Time interval

BOM for pump from January 1st until June 30th 1998BOM for pump from January 1st until June 30th 1998

301

Change no.EffectivityTime interval01.01.1998-30.06.1998

n As of Release 4.0 there is a time interval effectivity.

� You can determine the effectivity of an assembly for a period of time with an upper and lower limit.

n If you want to use time interval effectivity, you must use engineering change management.


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More Effectivity Types: Customized

BOM for customerBOM for customer

Change no.EffectivityCustomer B

Change no.EffectivityCustomer A

Change no.EffectivityCustomer C

n As of Release 4.0 there is an effectivity type that you can customize to suit your company's requirements.

n You define parameters, for example customer or airline, which are then linked to a data element. You can enter single values or open intervals in the assigned parameter type.

� You can combine the different effectivity types.

� This means that you can define the BOMs for serial numbers 1-10 as effective for customer A, BOM for serial number 11 as effective for customer B, and so on.

n If you want to use customized effectivity, you must use engineering change management.


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BOM Structure: Pump

Low-level code

0

1

2

Spiral casingSpiral casing

T-B00T-B00

ShaftShaft

100-300100-300

PumpPumpT-F00T-F00

FlywheelFlywheel

100-200100-200

2SlugSlugSlugSlugSlugSlugSlugSlug

n When you create a BOM, a low-level code is automatically assigned to each material.

n You can display the administrative data in the material master to find out the low-level code for a material.

n Low-level codes are used in material requirements planning (MRP) to determine the sequence in which materials are planned and by product costing to determine how costs are rolled up. Low-level coding takes account of the fact that a material may be used in multiple products and on multiple production levels of one product.

n When you create a BOM, a low-level code is automatically assigned to each material. Low-level coding collects the total requirements for a material on the lowest explosion level where it is used.


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Example: Pump

Blueprint and associated BOMBlueprint and associated BOM

3322

11

44

55

Unit ofmeasure

Description Material number

QtyItemnumber

PCSpiral casing T-B00 11

PCFlywheel 100-200 12

PCShaft 100-300 13

PCSupport 100-600 24

PCPressure lid 100-400 15

n The item numbers of the BOM components reflect the part numbers of the blueprint.

n Each part or assembly is a BOM item.

n The material number identifies each part or assembly.


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Check material typeCheck material type

Check material typeCheck material type

BOM Structure

HeaderHeader

1) Sub-item

2) Sub-item

...

Item

l Statusl Textl Lot size . . .

l Statusl Scrapl Textl Recursivenessl . . .

l Quantitiesl Installation pointl . . .

n Data maintained in a material BOM is managed through the following structure:

� You enter and maintain data that applies to the entire BOM in the BOM header.

� You enter and maintain data that applies to an individual component in an item.

� Sub-items allow partial quantities, installation points, and text to be defined for a BOM item. Sub-items have no functional data.


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BOM Status and BOM Item Status

BOM headerBOM header ItemItem

Field BOM statusField BOM status

Field item statusField item status

Permissible for

- MRP- Costing- Operation aassignment- Production orders- Coll. withdrawal- Sales orders

Exception messageHistory requirement

Relevant for:

- Design- Production- Plant Maintenance- Spare parts- Sales- Costing

MaterialMaterialBOMBOM

Application Application

n The BOM status controls BOM processing in different application areas. When you configure your system in Customizing under Bill of Material -> Define BOM status, you define the statuses for different indicators that allow or disallow BOM processing

Example:

BOM A: A BOM with status 1 can be exploded in MRP and released for a planned order.

BOM B: A BOM with status 2 cannot be exploded in MRP or released for a planned order.

n When you configure your system in Customizing (General data), you define which item statuses are allowed or disallowed for each BOM usage. You can define item status fields as required, optional, or disallowed for a specific area in your company.


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Item Categories

Stock itemStock item

Non-stock itemNon-stock item

Variable-size itemVariable-size item

Text itemText item

Document itemDocument item

Class itemClass item

PM structure elementPM structure element

Intra materialIntra material

n Each BOM item must have an item category assigned to it. The item category defines the characteristics and functions of a BOM item. It identifies when special data must be entered and it controls further system activities.

n The item category addresses the following questions, for example:

� Does a material have to be entered?

� Does it concern an item that supports a quantity-based inventory management?

� Which quantity sign is supported?

� Are sub-items defined?

� What do the screen selection and screen layout of the item detail screens look like?

n Note that you cannot change the item category after you have created the item. You can only correct an entry for the item category by deleting the item and then creating a new one.


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Finding a Material Number

List of classesList of classesOilColorsPumps

BOM item

Match-code KWhat is the number What is the number

of the material?of the material?

?

Material _____

BOMitem

Material _800-801

CharacteristicsCharacteristics

800-801 Color red800-802 Color red

Color redFinish matt

List of materials Paints

List of classesList of classes


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Non-Stock Item: Item category N

Item 40 and 50: Purchasing data

NN

- Price- Price- Cost element

- Material group- Purchasing group- Delivery time

Item Component Quantity Item cat.1020304050

T-B00100 - 200 100 - 300 ( without )100 - 400

1 piece1 piece1 piece1 piece1 piece

LLL

BOM T-F00

Fields relevant to MRP and costing

n You can create non-stock items both with and without a material master. If you create a non-stock item without entering a material number then you must enter a descriptive text and purchase data.

n You maintain purchasing data for non-stock items if they were created without a material master record. Using the cost data entered the system calculates the release strategy; the goods group is necessary for generating the purchase requisition.

n The component is directly procured for the production order. Purchase requisitions are created automatically.


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l Different dimensions, up to 3 sizesDifferent dimensions, up to 3 sizes

l Data relating to size determinesData relating to size determinescomponent quantitycomponent quantity

Variable-Size Item: Item Category R

Cutting a bar to size

n Enter this item category to represent parts of a material of different sizes under one material number.

n On the detail screen: After entry, the system calculates variable-size quantity of the material consumed by the component usage.

n Advantages:

� MRP can be executed by exploding the BOM without any additional work steps.

� You do not have to create a separate material master for each size.


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Variable-Size Item with Formula for a Cylinder

r = 0,8m

Circumference

2 � π � r 2

π � r 2

2 π � r � h

r = 0,8m

h =

1,2

m

Cutting measure

Surface area

n Entering a formula during variable -size calculation allows you to represent complicated calculations.

n You must maintain these formulae in Customizing.

n If there is no formula key, the system calculates: Size 1 * Size 2 * Size 3.


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MaterialMaterial

Document info record


MaterialMaterialMaterialMaterial Document

Document Item / Item category D


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Class Item / Item Category K

Classifiedmaterials

Red Blue Green Yellow...

MaterialMaterial

MaterialMaterialMaterialMaterial Class:Class:

Type 200/300Type 200/300

PAINTPAINT

Class:Class: PAINTPAINT



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Characteristic Value Assignment

ConstantConstant Example: 2,75 or OTTO or 123-KD-27

Example: Smith; Jones; Wilson

Example: 10 -27.3IntervalInterval

ConstantsConstants

Example: <20 up to and including 20Example: >14 from 14 upwardSpec. intervalSpec. interval

<10; 17; 19-23;>30CombinationCombination

Values are equal to the constant or lie within the interval

Values are not equal to the constant or lie outside the interval

Value includes string at any point

Comparison typeComparison type

n When determining a material number using the classification system, characteristic values can be defined several ways to determine the specific list of materials meeting the characteristic values.

n For instance you can:

� Link several entries in one line with an OR.

� Link entries in several lines with an AND.

� Use F4 help to display possible entries for selection criteria.


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Recursiveness

E1E1

K2K2K1K1 B3B3

E1E1 K3K3??

n A BOM is recursive if the product contains a component that has the same object number as the product. Recursiveness may be an error, but it can also be intentional.

n If the system recognizes the recursiveness online, you see the message: Error: BOM is recursive

n In exceptional cases, recursiveness can only be recognized by the update program. The person who creates the recursive BOM receives a message.

n If you want to create a recursive BOM, set the indicator recursiveness allowed in the BOM item.


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Configuration Sequence for BOMs

D

O

O

D

D

O

D

O

BOM header: BOM usage

BOM status

BOM usage / material types

Item categories / material types / object typesBOM item:

Variable-size item formulas

Spare part / material provision indicators

Default settings / parameters

User-specific settings

Other:

n Legend:

R = Required activity

O = Optional activity

D = Default available for activity


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Item Categories

Item categoriesItem categories

Material number

LL NN RR TT DD II K M K M

Inventory

Text item

Variable-size item

Document Item

Class item

PM structure element

Quantity signs (+/-)

Sub-items supported

Item screen sequence control

+ + + +

+ + + + +

. .

.. .

x x

x

x

x

x

x

x

x x x

1 3 2 1 1 1 1

- -

x

Intra material

n The following item categories are defined in the standard system:

� Stock item

� Non-stock item

� Variable-size item

� Text item

� Document item

� PM structure element

� Class item

� Intra material (PP-PI)


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Item Control Indicators

Item indicatorItem indicator

Bulk material

Discontinuation

Function controlFunction controlScreenScreen

S

B

B

B

S

B

B

B

S

Overhead material

Discontinuation control

Co-product

Alternative

Relevancy indicator

Explosion type

Phantom

Fixed quantity

Spare part/material provision

Planned as co-product

Items used as alternatives

Production, costing

Overrides material master control

Phantom assembly

Requirement same for any lot size

Material ,spare part provided

Status Engin./design, production, PMS

Recursive Recursiveness allowedB

n The various item categories can be combined with several indictors. Thus special procedures can be controlled.

Screens:

� S = Status screen

� B = Basic data

� You can set most control indicators in the material master. In general they are not copied to the BOM.

n You can make settings for MRP data on the general data screen for the BOM item that override the following indicators in the material master record:

� Do not explode Phantom assembly.

� Individual requirements

� Direct production (SOBSL 52)

� Long term planning


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BOM Deletion

l BOM deletion can be carried out using the:

n Delete function

n Deletion indicator

l You can:

n Delete the entire BOM

n Delete the item specified

l BOMs can be deleted:

n Without history

n With history using Engineering Change Management (ECH)

l Authorization groups control who may perform a deletion

n When you use the delete function, the BOM is removed from the system immediately, or on the valid-from-date of the change master record.

n If you set the deletion indicator in the BOM header, the BOM is deleted during the next reorganization run.

n Deletion at the header level removes the entire BOM, whereas deletion at the item level removes only the item specified leaving the remaining items intact.

n If you delete a BOM without history (without a change master record) the deletion is carried out immediately. Once the deletion transaction is updated, you can create a new BOM with the same material/plant/usage.

n If you delete a BOM with history (with a change master record) the system takes the valid-from date from the change master record as the deletion date.

n Before deleting a BOM, the system checks for:

� Items with object dependencies to ensure the change master supports dependency maintenance for configurable BOMs.

� Items with operation assignments. If assignments exist, the system displays the relevant message.

n See the documentation for more information on BOM deletion.


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Why Use Engineering Change Management?

For different objects

For the same or differentpoints in time

With special comprehensivedocumentation

Monitoring and documentation of changes

Planning and execution at a specific point in time

You can save several change statuses for the same object

Integration in the logical process chain

Combination of changes that belong together

n Engineering Change Management is a central logistics function that can be used to change redundant master data and document the changes.

n By using a valid-from date for the change master record (or for the ECR/ECO), the changes become valid on a predefined date. This aids long-term planning.

n You can use Engineering Change Management to store SAP objects (for example, BOMs, routings) more than once. This means that the objects can be stored in all relevant change statuses.

n The changes take effect automatically at the predefined time in all areas of the logistics process chain, for example, sales order, material requirements planning and production control.

n You can use Engineering Change Management to group together changes to different SAP objects that are affected by one change. You can change all the objects at the same time, or you can define different change dates for individual objects. You can create general documentation for the change and also special documentation for each specific object change.

n You can use Engineering Change Management to fulfil your legal obligations to document changes.


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Engineering Change Management

old

new

+

old

new

old

new

Changedocuments +

Without history With changedocuments With history

Changedocuments

n You can make object changes (for example: BOM and routing changes) in the SAP System either with or without history. However, you should be aware that change documents are created by the system even for changes without history.

� Without history: These are changes that do not have to be documented because they take place during the development stage of the product, for example. The status of the object before the change, is not saved. You can only find out about the status of the object before the change by using change documents.

� Changes with History: These are changes that must be documented because they take place during production, for example. Both the status before and after the change is saved. The system creates change documents. For some objects, these change documents differ from those created for changes without history. Engineering Change Management in the SAP System enables you to document changes completely. Some of these changes may be needed for product liability purposes, for example.


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?_______________

WhenWhen does the change occur?

What is the status afterafter the change?

Change on 08/20/00Change on 08/20/00What was the status beforebefore the change ?

WhyWhy does the change occur?

Bill of material from to Item Comp 20.08.00 10 x 31.12.00

Bill of material from to Item Comp 01.05.93 10 x 20.08.00

Changes With History

n Changes with history (changes with reference to a change number) become effective on an exact date.

n The changed object is saved twice: once in the pre-change state and once in the post-change state. The pre-change state ends with the valid-to date and the post-change state begins with the valid-from date.

n You can document changes in several different ways.


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Object Type Indicators: Change Master Record

Bill of material

Task list

Document

Material

Characteristic

Class

...

...

Object type Active Object MgtRec. Gen.new Gen.Dia Lock

b

b

b

b

b

b

The following indicators control processing with the change number for the individual object types:

n Active = object type for the change number is active. You have to set this indicator if you want to process objects of the object type concerned with the change number.

n Object = an object management record is required for each object. If you set this indicator, then you can only make a change to an object of the object type concerned if you create an object management record for the object first.

n MgtRec. = object management record is generated. If you set this indicator, the system automatically generates an object management record when you process (create or change) an object of the object type concerned with the change number. If you set this indicator, you can make changes to all objects of the object type concerned with the change number.

n Gen.new = object management record is only generated automatically when you create an object for the first time. If you set this indicator, an object management record is only created automatically when you create an object of the object type concerned. If you want to process an existing object with the change number, you first have to manually create an object management record.

n GenDia = object management record is only generated automatically when you create an object management record for the first time. When the object management record is generated automatically, the system branches to a dialog box where you can enter object-specific documentation. (Exception: sales order BOM).

n Lock = object type locked for changes: You can lock and unlock the object type as required.


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BOM Management: Unit Summary


l Create a BOM with different effectivities for thematerial, plant and usage.

l Use different item categories to control furthersystem activities.

l Use the BOM status to control BOM processingin different application areas


Exercises

Unit: BOM Management

Topic: BOM basics


• Create a group BOM and assign it to other plants

• Create, change and display BOM basic data

The engineering/design department creates a group BOM. This BOM is to be made effective in other plants by using plant assignments. Because the BOM in plant 1000 is not identical to the group BOM, a plant BOM is maintained in this plant.

1-1 Create a group BOM for material T-F## (## = group number).

Note the following when you create a group BOM:

Material: T-F##

Plant: ‘blank’ (group BOM without entry for plant)

Use: 1 (Production)

Alternative: No entry

Valid from: Today's date

1-1-1 Which system message do you get, and why? (only for newly created and assigned material statuses)

1-1-2 The following items should exist for BOM T-F##: Item no. Component Quantity Item cat. Sort string

10 100-100 1 Stock item A5

20 100-200 2 Stock item A1

30 100-300 1 Stock item A3

Save the BOM and display the material item overview in the change mode. Go to the BOM header and make a note of the internal BOM number:

Enter a 4 line BOM text of your choice.


1-1-3 You are not sure if the fly wheel of your pump is correct. Branch to the material master record so that you can check the material group. Do not exit the current transaction and do not create another session.

What is the name of the material group? _________

1-2 Assign the group BOM to plants 1000 and 1100.

1-2-1 Why can you not assign it to plant 1100 ? ____________________________________________________________

____________________________________________________________

1-2-2 Go to the BOM header of plant 1000. What is the internal BOM number? ____________________________________________________________

Why ?_______________________________________________________

1-2-3 Explode the plant assignment (plant 1000) and create a plant BOM for T-F## in plant 1000. Use the group BOM as a template. Replace assembly 100-100 with material T-B## in item 10. Change the component quantity of item 20 from 2 to 1. Display the material item overview. Which components are assemblies themselves? ____________________________________________________________ Maintain item 20 as a spare part with the indicator A. (see the detail button) Sort BOM T-F## (plant 1000) according to a sort string.

1-3 Create assembly T-B## in plant 1000 as follows:

Item no. Component Quantity Item cat. 10 100-110 1 piece Stock item 20 100-120 1 piece Stock item 30 100-130 1 piece Stock item

1-3-1 Display the item overview. OPTIONAL:

1-3-2 Ensure that in the BOM text, Ms. Smith is responsible for the assembly.

1-3-3 What is the BOM status? _______________ Does this status allow the BOM to be used in costing? _________________________________________________________

1-3-4 In the appropriate field enter laboratory KB1 as being responsible for the BOM(header: additional data). Save your BOM.


Exercises


Topic: Bill of Material Maintenance


• Process other BOM items according to item category

The plant BOM is extended by different items according to requirements.

1-4 Extend your plant BOM T-F## in plant 1000 from the previous exercise with the following data:

1-4-1 Item no. Component Quantity Item cat. 40 100-600 2 piece Stock item

The 2 support bases are assembled on the pump. A support base should be assembled at the front and the back of the pump. Create sub-items for this.

1-4-2 Item no. Component Quantity Item cat. 50 1 piece Non-stock item

Item text: "A non-stock item" Purchasing org.: 1000

Price: 10 UNI Purchasing group: 000 Superior Cost element: 415000

Material group: Metal processing

1-4-3 Item no. Component Quantity Item cat. 60 100-700 1 piece Variable-size item Variable size 1 200 mm

Variable size 2 300 mm Note the calculated variable-size item quantity. Change variable-size 2 to 400 mm. Recalculate the variable-size item quantity.


1-4-4 Item no. Component Quantity Item cat. 70 100-130 10 piece Stock item

Maintain this item as bulk material.

1-4-5 Item no. Document Type Part Version Quantity Item cat. 80 T-F1## DRW 000 00 1 piece Document 1-4-6 Display the BMP files associated with this document.

Save your BOM.

1-4-7 Display your BOM T-F## with 15 as the required quantity. How many M10 screws (100-130) are needed? _________________

1-4-8 Which components are marked as assemblies?

1-4-9 Who created the BOM? And on what date?


Exercises


Topic: Customizing BOMs


• Set the status, application and use of a BOM

• Set user default values

The SAP System is adapted to suit company and user-specific requirements.

1-5 Which order of priority do the BOMs have with selection ID (Sel.ID:01) regarding BOM usage?

1-6 Which selection ID does BOM application CAD1 use?

Which BOM usage has the highest priority here?

1-7 Maintain the default settings for you user so that:

The item numbers increase in increments of 10.

Item category L is the default for material items.

Item category D is the default for document items.

1-8 When using BOM usage: 'Universal', which fields are marked as required fields?

1-9 Create a new BOM status, which can not be used in routings

The new BOM status number should be your group number +10 (##+10)


Solutions


Topic: BOM basics

1-1 Create material BOM

Logistics → Production → Master data → Bills of material → Bill of material → Material BOM → Create:

Material: T-F## Plant: LEAVE BLANK (Default) Usage: 1 (Default) Valid from: Today's date (Default)

1-1-1 ‘W: Group BOM’ because no plant is specified.

You may also see a warning message regarding your material status if you performed the optional exercise in the previous unit

Acknowledge all warning messages by selecting: Enter

1-1-2 Enter the following components in the item overview:

Item no. Item cat. Component Quantity Sort String 10 Stock item 100-100 1 A5 20 Stock item 100-200 2 A1 30 Stock item 100-300 1 A3 Save your BOM.

From the same screen:

Material BOM → Change

Select: Enter

Select: Header

Record the internal BOM number:

Select: BOM Long text

Enter four lines of text of your choice.

Select: Back


1-1-3 Select: Item Overview button Select the component 100-100 and choose: Environment → Display Material → Engineering/Design Material master view: Basic data 1

Material group: 001 (metal processing)

Select: Back

Select: Save

1-2 Assign the group BOM to plants 1000 and 1100.

Logistics → Production → Master Data → Bills of material → Bill of material → Material BOM → Plant Assignment →Create

Select: Enter

Select: New Assignments

Material: T-F##

Plant : 1000

BOM Usage: 1

Select: Save

1-2-1 Repeat the procedure and try to assign the BOM to plant 1100 “Material T-F## is not maintained in plant 1100”

Select: Cancel

Select: Save


1-2-2 Logistics → Production → Master Data → Bills of Material → Bills of Material → Material BOM → Display

Material: T-F##

Plant: 1000

BOM usage: 1

Select: Enter

Select: Header

The internal BOM number in plant 1000 is the same as the number from part 1-1-2. A reference has been set up. The BOM structure is saved under a number in the system.

1-2-3 Change the plant assignment.

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Plant Assignment →Change

Material: T-F## Plant: (Leave blank) BOM Usage: 1

Select: Enter

Display all assignments.

Select: All Allocations to BOM.

Select the assignment to plant 1000.

Select: Delete Allocation

Select: Yes

Select: Back

Select: Save

Create the plant BOM as follows:

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create

Material: T-F## Plant: 1000 Usage: 1 Valid from: Today's date

NOTE: On the create screen, use the Copy from function.

Material: T-F## Plant: Leave BLANK Usage: 1 Valid from: Today's date

Select: Enter


Acknowledge all warning messages by selecting: Enter

Select: Select All

Select: Copy

Change item 10 to material T-B##

Change quantity of item 20 to one.

Mark item 20.

Select: Item (puzzle piece)

Select: Status/long text tab

Spare part indicator: A (Spare part customer A)

Select: Back

• Materials 100-200 and 100-300 are assemblies (ý Asm).

• Edit → Sort → Sort by sort string

• Save the BOM.


1-3 Create BOM

Logistics → Production → Master data → Bills of material → Bill of material → Material BOM → Create:

Material: T-B## Plant: 1000 Usage: 1 Valid from: Today's date

Select: Enter

Item no. Item cat. Component Quantity 10 Stock item 100-110 1 20 Stock item 100-120 1 30 Stock item 100-130 1 Select: Header Select: Quantities / Long text tab

BOM text: Ms Smith is responsible for the assembly

1-3-3 BOM status 1 (Active) (bottom right of header) Yes it is released for costing

(See this by marking the BOM status field and selecting F4)

1-3-4 Select: Header

Select: Further data tab page

Laboratory / Office: KB1

Select: Save


Solutions


Topic: Bill of Material Maintenance

1-4 Change material BOM T-F##.

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change

Material: T-F##

Plant: 1000

BOM Usage: 1

Select: Enter

1-4-1 Item 40 L 100-600 2

Select item 40 and choose the button: Subitems

Item Description Quantity Text

Item 1 Pump front 1 Use it in the front

Item 2 Pump back 1 Use it in the back

Select: Back or use F3

1-4-2 Item 50 N (no component #) 1

Select: Enter

Item text: "A non-stock item"

Select: Enter

Purchasing organization: 1000 Price: 10 UNI Purchasing group: 100 (Corporate Purchasing) Cost element: 415000 Material group: 001 metal processing

Select: Enter


1-4-3 Item 60 R 100-700 1

Select: Enter

Size 1: 200 mm Size 2: 300

Select: Enter

Variable size item quantity: 0.060 m2 (is calculated for you)

Change size 2 to read: 400 NOTE: Delete variable-size item quantity calculation of 0.060 before you:

Select: Enter so that:

Variable-size item quantity: 0.080 m2 (is re-calculated for you)

1-4-4 Item 70 L 100-130 10

Mark item 070

Select: Detail

Select: Status/long text tab

ý Bulk material (bottom right) (Select) ¨ Costing Relevance (Deselect)

Select: Back

1-4-5 Item 80 D

Select: Enter

Document: T-F1##

Document Type: DRW

Part: 000

Version: 00

Quantity: 1

Item Category: D

Select: Enter

1-4-6 Display the document items

Mark item 80

Environment → Display Document

Select individually each BMP file listed to display the associated file.

Select: Back when you have finished to save the BOM.

Select: Save


1-4-7 Display material BOM

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Display

Material: T-F##

Plant: 1000

BOM Usage: 1

Required quantity: 15 (bottom line)

Select: Enter

150 M10 Screws (100-300) are needed.

1-4-8 Assemblies: T-B## 100-200 100-300

1-4-9 Select: Header

Select: Administrative data tab

Created by: lo205##

Created on: Today


Solutions


Topic: Customizing - BOM

1-5 Order of priority

Tools → Accelerated SAP → Customizing → Edit Project

SAP reference IMG button

Production → Basic Data → Bill of Material → Alternative Determination → Define order of priority for BOM usages:

Priority for Selection ID 01:

Priority 1 Usage 1 (Production)

2 Usage 3 (Universal)

3 Usage 2 (Engineering)

Note: use the F4 key to see the descriptions.

1-6 BOM application



Customizing → Production → Basic Data → Bill of Material → Alternative Determination → Define applications:

Application CAD1 (CAD design) Selection ID 02

Mark Sel ID field

Select: F4

BOM usage 2 Engineering/design has the highest priority


1-7 Default values



Customizing → Production → Basic Data → Bill of Material → Define user-specific settings:

Select : New entries

User: lo205-##

Item increment: 010

Material item category: L

Document item category: D

Select: SAVE

1-8 Customizing → Production → Basic Data → Bill of Material → General Data → BOM usage → Define BOM usages

Note that when using BOM usage: Universal there are no required fields set.

All fields are set to optional or no entry.

1-9 Tools → Accelerated SAP → Customizing → Edit Project


Customizing → Production → Basic Data → Bill of Material → General Data → Define BOM status:

Select: New entries

Status: Group ## + 10

Mark all columns EXCEPT Release Work Schedule

Select: SAVE


SAP AG 1999

l BOM explosion

l Where-used listsl BOM comparisons

l Mass changesl Product structure

Contents:

BOM Reporting Functions


SAP AG 1999

l Work with BOM explosions, where-used lists and BOMcomparisons

l Navigate with the product structure display

l Navigate with the product structure processing

l Use mass change functions to change several objects


SAP AG 1999

BOM Reporting Functions: Topic Objectives


SAP AG 1999

l The structure of a BOM has to be checked.

l A material / item has to be substituted.

l All objects in a structure have to be displayed,processed or created.

BOM Reporting Functions: Business Scenario


SAP AG 1999

E 1E 1 E 2E 2

T 1T 1 T 3T 3T 2T 2

B 1B 12 3

4 53

24

Product

BOM level by level Multi-level structure Summarized BOM

E 1

Material QuantityT1T2B1T2T3

234

168

Material Quantity Material Quantity.1 T1.1 T2.1 B1..2 T2..2 T3

234

168

B1T1T2T3

42

19*8

BOM Explosion

n The BOM explosion answers the question: What does a product consist of? This question arises in various situations, such as when:

� You need to determine requirements for a product

� The engineering department needs to look at the overall structure of a product

� You need an overview of all the necessary parts and materials

� You need to calculate costs or effects of cost changes

n The BOM application defines the following criteria for the search procedure:

� Priority of BOM usage

� Priority of a specific alternative for a particular multiple BOM

� Production versions in the material master

� Checks for particular status indicators

n In your user master record you can enter a default value for the BOM application. This value is the SET/GET parameter CSA.


SAP AG 1999

? ?? Where is ?

? ? ? ?

Where-Used Lists

n Where-used lists can be generated for:

� Work centers

� Capacities

� PRTs

� Reference operation sets

� Materials

� Documents

You can use the object overview to select the list you require.


SAP AG 1999

E 1E 1 E 2E 2

T 1T 1 T 3T 3T 2T 2

B 1B 12 3

4 53

24

Component:

Material Quantity

112

2

B1E1E1E2

T2

Level

43

16

20

Single and Multi-Level Material Where-Used Lists

n The where-used list provides an answer to the question: Where is a material used and in what quantity? This question arises especially where there are a lot of multiple -use parts and materials.

n Examples of why the information is required are:

� To calculate the requirements for a particular material.

� To find the products that are affected by changes to the individual parts.

� To find the assemblies produced late due to delayed delivery of a raw material for example.

� To calculate the cost effects on a product if raw materials costs change.


SAP AG 1999

E 1E 1 E 2E 2

T 1T 1

T 2T 2T 2T 2

B 1B 1

T 2T 2

T 3T 3

B 1B 1

T 2T 2

T 3T 3

T 3T 3

4

3

2

16

8

5

20

10

3

3

==

=

=

BOM Comparisons

n The BOM comparison is useful if:

� Several BOMs exist for a material,

� With different uses,

� And/or with different change statuses.

n The comparison can be single -level or multi-level.

n You can select which fields you want to compare.


SAP AG 1999

10

20

30

. . .

. . .

. . .

10

20

30

. . .

. . .

. . .

10

20

30

. . .

. . .

. . .

10

20

30

. . .

. . .

. . .

BOMsBOMs

ininselectedselected

Components XYComponents XYreplacedreplaced

bybycomponent Zcomponent Z

Mass Change in BOMs

n You can use the mass change function to make changes to items in several BOMs.

n The following item changes are supported for material, document and class items:

� Changing the component quantity

� Changing the item data

� Adding items

� Replacing items

- in all chosen BOMs

- and assign a new item quantity, if desired

- using engineering change management, if desired

- with restricting selection criteria, such as plant and/or usage.

� Delete an item

- in all chosen BOMs

- using engineering change management, if desired

- with restricting selection criteria, such as plant and/or usage.


SAP AG 1999

P-100Mat

Display Product Structure

1000 1

REV P-100 ADocumentsDOC P-100 DRW 000 00

DRW 000 01

BOMsProductionEngineering

ASS 100-100100-200

100-200Mat

100-300100-400

100-410Mat100-420Mat100-430Mat100-431Mat

Revision levels

P-100KP-100

DRW 000 00DOCDOC

ASS

ASSASS

100-500100-600100-700P-100P-100K

Pump GG Standard 150-200

PP-AE1 01.01.1997 Design change

Assembly drawing Standard Pump 150-200Assembly drawing Standard Pump 150-200CH Control drawing Pump

100010001000

100010001000100010001000

Spiral casing GGFly wheel GGSlug for fly wheel GG

ShaftPressure cover GGSlug for pressure cover GGPacking sealSafety ring

1000DRW 000 00DRW 000 00

1000 Bearing case1000 Support

Sheet metal ST37Assembly drawing PumpControl drawing Pump

MatMatDocDoc

ASS

Product Structure

Slug for fly wheel GG

Retainer ring

n The product structure enables you to display and process all related objects (for example, material, BOM, document, routing). The product data is displayed in a tree structure. You can limit the structure to display only the detail data that is required for the current processing situation.

n You can explode the product structure across systems. Data can be evaluated and processed over several systems (ALE destinations).

n You can:

� Go directly to display mode for specific objects

� Display or process similar objects

� Create an additional tree structure for any object

� Select several objects for the object management records of engineering change management.


SAP AG 1999

BOM Reporting Functions: Unit Summary

You are now able to:l Analyze BOM structures using BOM explosions, where-

used lists, and BOM comparisons.

l Make changes quickly and easily in more than one BOMusing the mass change function.

l Display and process all objects belonging to a productusing the product structure function


Exercises

Unit: BOM Reporting Functions

Topics: BOM explosion and BOM comparison


• Analyze your plant BOM using the BOM explosion functions

The engineering/design department checks the BOMs created.

1-1 To answer the following questions on your BOM T-F##, use the BOM explosion function with the BOM application for Production – general.

1-1-1 Which items in BOM T-F## (plant 1000) have the spare part indicator A? _________________________________

1-1-2 Which items in BOM T-F## are spare parts? _________________________________

1-1-3 Which item is produced externally (non-stock item)? _________________________________

1-1-4 Which item is handled as bulk material? _________________________________

1-1-5 How many hexagonal head screws M10 (100-130) are used in BOM T-F## for 10 pumps?_________________________________

1-1-6 Which components are used in more than one BOM level structure for the T-F## ? _________________________________

1-1-7 Which materials are the hexagonal head screws used in? _________________________________


1-2 Compare your BOM T-F## in plant 1000 with the group BOM for T-F## single-level and differentiated with usage 1.

1-2-1 Which items are similar?

1-2-2 Select just the object short text (description) as fields for comparison.

1-2-3 Repeat the comparison.

1-2-4 Which items are similar now? Reset the fields.

1-3 Compare your BOM T-F## (plant 1000) with BOM P-100 (plant 1000) multi-level and summarized with application PP01.

Compare document items only.

List the drawings that are listed in the comparison:


Exercises


Topic: Product Structure


• Analyze and correct your product structure

The design engineer wants to see all objects in his pump structure and process them according to requirements.

1-4 Look at the product structure for material T-F##.

Display the BOM for the assembly and a document info record.

1-5 Change item 10 and 30 for BOM T-F## in plant 1000 as follows: Item 10 should also be effective as a spare part for customer A. Lately there have been many problems with quality. For item 30 add special text to read: Examine the shaft key slot for burrs.

1-6 Go to classification view of the material T-F## and display the characteristics of the pump.Pump height (forderhohe): ____________ Pump capacity (forderleistung): ____________ Usage (verwendung): ____________


Solutions


Topics:

• BOM Explosion

• BOM Comparisons

1-1 BOM explosion

Logistics → Production → Master Data → Bill of Material → Evaluations → BOM Explosion → Material BOM → BOM (multilevel) or

Logistics → Central Functions → Engineering → Bill of material → Evaluations → BOM Explosion → Material BOM → BOM (multilevel)

Material: T-F## Plant: 1000 Application: PP01

Select: View

1-1-1 Spare part ID A Select: Execute Only the Fly wheel: 100-200 is a spare part for customer A

1-1-2 Back with F3 (Delete spare part ID) Spare part sel. X Select: Execute Only the Fly wheel: 100-200 is marked as a spare part.

1-1-3 Back with F3 (Spare part sel. X delete)

Item category N Select: Execute Item 50 non-stock item

1-1-4 Back with F3 (delete item category N) Bulk material X Select: Execute Item 70 100-130 Hexagonal head screw M10

1-1-5 Back with F3 (Delete bulk material X) Back with F3 Required quantity: 10 Select: Execute 100 100-130 M10 screws are required

Select : Back


1-1-6 Summarized BOM

Logistics → Production → Master Data → Bill of Material → Evaluations → BOM Explosion → Material BOM → Summarized BOM

or Logistics → Central functions → Engineering→ Bill of material → Evaluations → BOM Explosion → Material BOM → Summarized BOM

Material: T-F## Plant: 1000 Application: PP01 Select: Execute The screws 100-130 11 *PC (PC = piece)

The asterisk designates that this is a summarized quantity

1-1-7 Where-used list

Logistics → Production → Master Data → Bills of Material → Evaluations → Usage → Material or Logistics → Central functions → Engineering→ Bill of material → Evaluations → Usage → Material

Material: 100-130 Direct: Select Material BOM: Select Select: Next Page Select: Execute

1-2 BOM Comparisons

Logistics → Production → Master Data → Bills of material → Evaluations → BOM Comparison or Logistics → Central Functions → Engineering→ Bill of material → Evaluations→ BOM Comparison

1-2-1 Primary

Material: T-F##

Plant: (LEAVE BLANK)

Usage: 1

Secondary

Material: T-F##

Plant: 1000

Usage: 1

Select: diff. Comparison

Item 100-200 is listed as similar. (The red Not Equal symbol)


1-2-2 Select: Back or use F3

Go to → Fields to compare:

Select just the object description as comparison criterion and repeat the comparison.

Select: Save

Select: Copy (Enter)

Select: diff. Comparison

Items 20 are now the same because the quantities are no longer being compared.

1-2-3 Select: Back or use F3

Go to → Fields to compare: Select: Reset

Select: Copy (Enter)

1-3 BOM comparison→ Multi-level comparison.

Select: Multi.level Comparison

Select: View

Item category: D

Select: Continue

Primary

Material: T-F##

Plant: 1000

Application: PP01

Secondary

Material: P-100

Plant: 1000

Application: PP01

Select: Summarized comparison

Record the drawing identifiers that are listed in the comparison:

T-F##

P-100


Solutions


Topic: Product Structure

1-4 Call up the product structure browser

Logistics → Central Functions → Engineering Change Management → Environment → Product structure:

or

Logistics → Central functions → Engineering → Environment → Product structure:

Enter material number T-F##

Select: Enter.

Explode the tree structures for documents and BOMs by selecting the triangle symbol.

By double-clicking on the material or document number, the appropriate records are displayed.

By selecting the individual objects and clicking on the right mouse button, a context menu is displayed. The objects can be displayed, changed or navigated into the Engineering Workbench (i.e. Create Work Item) from the context menu.

1-5 Open the tree structure of the BOM T-F## for plant 1000 down to the item level. Select

the header of the BOM and click on the right mouse button.

Choose Change.

Select: Enter

Mark item 10

Select: Detail

Select: Status Long text tab

Spare part indicator: A

Select: Back

Mark item 30

Select: Detail

Select: Status Long text tab

Text: Examine the shaft key slot for burrs.

Select: Back

Select: Save


1-6 From the Product structure:

Select: T-F##

With the right mouse button, select Display

Select: Classification

Select: Enter

Select: 001 Material Class (if necessary)

Select: Enter.

Class: 100

Characteristics: Pump height (forderhohe): 10 m Pump capacity (forderleistung): 20 m³ Usage (verwendung): Haustechnik


SAP AG 1999

l Variant BOM

l Multiple BOMl Variant Configuration

Contents

Variants and Alternatives


SAP AG 1999

l Evaluate the purposes of variant BOMs and multiple BOMs

l Maintain variant and multiple BOMs

l Distinguish between variant BOMs and variant configuration


SAP AG 1999

Variants and Alternatives: Topic Objectives


SAP AG 1999

l For additional BOMs, the variant BOM and (or)the multiple BOM should be used

l For the planing of complex products that canexist in several variations, the variationconfiguration should be set.

Variants and Alternatives: Business Scenario


SAP AG 1999

Variant BOM

Alternative 1

Alternative 2

Multiple BOMSimple BOM

Technical Type

n Simple BOM: (Technical type '_') A BOM without variants or alternatives.

n Variant BOM: (Technical type 'V')

� Group of BOMs that enable you to describe a product, or several products that have a large proportion of identical parts.

� Each variant is a finished product with all its components and assemblies.

� Several products that are created as variants in a variant BOM are grouped together as a BOM group and stored together under one internal number.

n Multiple BOM: (Technical type "M") A group of BOMs representing a single product that can be manufactured from different combinations of materials (alternatives).

n The system enters a technical type and this can not be changed once it has set.


SAP AG 1999

Variant BOM: Several Products

Pump OilOil

Pump WaterWater

Pump Waste waterWaste water

Casing GGCasing AUCasing AU

CasingCasing(steel(steeltop)top)

FlywheelFlywheel

BearingBearing

BearingBearing

Non-variableparts

10

20 30Variantparts

ShaftShaft

Shaft

SlugSlug

ShaftShaft

ShaftShaftassemblyassembly

n If several similar products are manufactured, whose parts only differ in minor ways, then you can represent these various products using a variant BOM. Variants can also differ in component quantity alone.

n Only a simple (basic) material BOM can be extended to become a variant BOM. You cannot convert a multiple BOM into a variant BOM.


SAP AG 1999

BOM header for each variantBOM header for each variant

Different material number for each variantDifferent material number for each variant

Up to 99 variantsUp to 99 variants

Variant BOM "V"

Several products 1 internal BOM

Variant BOM

n A product can be created as a variant BOM if:

� A BOM does not already exist for the material.

� The BOM that you want to create a variant of cannot be a multiple BOM.

� The base unit of measure of the product and the product's BOM base quantity is the same as the base unit of measure of the variant. A variant can not be created from a multiple BOM.


SAP AG 1999

Variant BOM

BOM groupBOM groupPump LO205Pump LO205

Plant:Plant: 10001000 Usage:Usage: 11

Material:Material: 11T-F00T-F00

Material:Material: 22T-T-FxxFxx

Material:Material: 33T-F88T-F88

Variant 1 Variant 3

Variant 2

Up to 99 variants

Variant BOM "V"

n The field BOM group can also be used as an external BOM number.

n Several products created as variants of a variant BOM are saved under one internal BOM number. You can give a name to all of the variants of one variant BOM by entering a BOM group in the BOM header. Each variant has its own material number.

n The plant and the BOM usage uniquely identify a variant BOM.

n Each variant has a BOM header.

n A product can be created as a variant BOM if:

� A BOM does not already exist for the material.

� The BOM that you want to create a variant of cannot be a multiple BOM.

� The base unit of measure of the product and the product's BOM base quantity is the same as the base unit of measure of the variant. A variant can not be created from a multiple BOM.


SAP AG 1999

10

20 30

Identical part

Alternative part

T-F77Color blue

Alternative 1Alternative 1 LOT SIZELOT SIZE 1 - 1001 - 100Alternative 2Alternative 2 LOT SIZELOT SIZE 101-200101-200

Alternative 3Alternative 3 LOT SIZELOT SIZE

PIGMENT 1 T-B73

201-1000201-1000

PIGMENT 3 T-B71

PIGMENT 2 T-B72

SolventT-B74

WaterT-B75

Multiple BOM: One Product

n A product can be made of different combinations of components, depending on the quantity (lot size) to be manufactured. This type of product is represented by alternative BOMs (alternatives). These BOM alternatives only differ slightly from one another, usually in terms of the component quantity.

n A variant BOM cannot be converted to a multiple BOM.


SAP AG 1999

Multiple BOM

T-F77T-F77Alternative 2Alternative 2

BOM groupBOM groupcolor:color: blueblue

Plant:Plant: 10001000 Usage:Usage: 11

T-F77T-F77Alternative 1Alternative 1

T-F77T-F77Alternative 3Alternative 3 Approx. 1000 alternatives

Multiple BOM "M"

n The field BOM group can also be used as an external BOM number.

n All the alternatives for a multiple BOM are saved under one internal BOM number. You assign one name to all alternatives in a multiple BOM by entering a BOM group in the BOM header.

n The plant and the usage uniquely identify a BOM.

n Each alternative has a BOM header.

n Choosing the alternative using the material master record:

� Lot size

� Date

� Production version


SAP AG 1999

SimpleSimple VariantVariant MultipleMultiple

ProductProduct

Internal Internal BOM BOM

numbernumber

Technical Technical typetype

Variants/Variants/AlternativesAlternatives

one n similar one

one one one

‘ ‘ 'V' 'M'

‘01’ Variant for each Alternative‘01’, ‘02’, ‘03’Product

Comparison of BOM Categories


SAP AG 1999

Pump type• Piston• Rotary• Vane

Connections• Square flange• Round flange (2 hole)• Round flange (4 hole)• Other

Direction of rotation• Left• Right• Variable

Color• blue• black• red

Drive• Manual• Electric

Delivery head• 2 - 20 m• 2 -54.68 yd

Medium• Oil• Water

Circuit type• Open• Closed

Variant Configuration

n Variant configuration is used to support the manufacture of a product whose bill of material and/or routing varies based on options selected by the customer.

n Complex products mean complex configuration tasks in both sales and production. However, a company that sells or produces variant products must perform these tasks quickly and accurately. This is not easy, as product development cycles and life cycles of products become shorter than ever before.

n Standard product is a general term used to define a product that is to be manufactured with several variants. It covers all the different features of the variant products and therefore does not refer to any one particular article.

n The features of configurable products are defined as characteristics in the SAP System.


SAP AG 1999

Super BOMSuper BOM

Configured routingConfigured routingSuper routingSuper routing Object Dependencies

Configured BOMConfigured BOM

Configuration of a Pump

n There are often inter-dependencies between the individual forms of a product. It is frequently the case that not all combinations that are theoretically possible can be allowed practically. This may be due to the following two reasons:

� Some combinations are not possible for technical reasons.

� Other combinations may not be allowed for marketing and sales reasons. For example, if you want to order a motor cycle, you may only be able to have certain colors of paints and seats if you are ordering an expensive model.

n Instead of creating a separate BOM for each product variant, you can group the components together into a super BOM. This super BOM consists of parts that appear in all variants of the product, and others that can be chosen and included in the product depending on the variant. You use object dependencies to define which components are chosen under which conditions.

n When you maintain the sales order, a special product structure is created dynamically.


SAP AG 1999


l Use other BOM types (variant and multiple BOMs)

l Recognize the difference between variant BOMs andvariant configuration

Variants and Alternatives: Summary


Exercises

Unit: Variants and Alternatives

Topic: Variant BOM


• Process variant BOMs and recognize the difference between variant BOMs and variant configuration

The engineering/design department requires BOMs for simpler, but similar materials.

1-1 You should now create two additional variants in plant 1000 with the usage 1 for pump T-F##, which already exists. These are pumps T-FY## and T-FZ##.

Please use the following data when you create variants of T-F## (Create variant of):

BOM text: "Standard pump" group ##

1-1-1 In variant pump T-FY## replace item 10: T-B## with item 10 assembly T-B1##.

1-1-2 In variant pump T-FZ## replace Position 30: 100-300 with item 30 assembly T-BZ##.

1-2 Display all variants of T-F##. BOM group

Add a BOM group identifier to this BOM Group of Group## Variants

Note the following for each of the variants in this group.

Field T-F## T-FY## T-FZ##

Internal BOM number

Technical type


1-3 Enter a BOM item 100-801 directly in the BOM group maintenance that is only valid for the variants T-FY## and T-FZ##.

1-3-1 Check the result to see if the new item appears as a material component for each BOM.

Is the red paint now listed as a component for each Material?


Exercises


Topic: Multiple BOM


• Maintain a multiple BOM

Recipes for blue paint are grouped together in a multiple BOM.

OPTIONAL:

1-4 The recipe for blue paint (material number T-F77## (## = group number) has different components or component quantities for different lot sizes.

1-4-1 Create a finished product T-F77## in plant 1000 by copying from the reference material T-F77.

1-4-2 Create a BOM for the recipe and two alternatives with the following data:

Material T-F77##, BOM text ‘multiple BOM group ##’

Item no. Component Quantity UN Item cat.

10 T-B71 0.5 kg Stock item 20 T-B74 1 l Stock item 30 T-B75 1 l Stock item

1-4-3 Create an alternative (copy alternative 1). In this alternative, replace item 10, component T-B71 with:

Item no. Component Quantity UN Item cat. 10 T-B72 0.3 kg Stock item

Also change the quantity of component T-B74 in item 20 to 1.4l.


1-4-4 Create another alternative (copy alternative 1) and replace item 10, component T-B71 with:

Item no. Component Quantity UN Item cat. 10 T-B73 0.3 kg Stock item

1-4-5 Add the following data to the header of all alternatives:

Alternative Alt. Text Lot size from to

1 1. Mixed paint 1 100 2 2. Mixed paint 101 200 3 3. Mixed paint 201 500

1-4-6 Add the BOM group identifier of: Group ## Paint to the BOM Group. Also display all alternatives of T-F77## and record the following data.

Field Alt.1 Alt.2 Alt.3

Internal BOM number

Technical type

Alt. Text

Lot Size Range

1-4-7 Use the Engineering Product Structure browser for material T-F77##, BOM alternative 01. Change the quantity of item 30 from 1 to 2. Save when you have finished.

The menu path is provided for your convenience

Logistics → Central functions → Engineering → Environment → Product structure.


Solutions


Topic: Variant BOM

1-1 Create additional variants for pump T-F##.

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM→ Create: or Logistics → Central Functions → Engineering→ Bills of material → Bill of material → Material BOM→ Create:

Material: T-FY## Plant: 1000 Usage: 1 Valid from: Today's date

Select: Create variant of

Material: T-F## Select: Enter Select: Select all Select: Copy

Select: Header

BOM text: Standard pump Group ##

Select: Enter

1-1-1 In Item overview, overwrite item 10 to read:

Item no. Item cat. Component Quantity 10 Stock item T-B1## 1

Select: Save


1-1-2 Repeat the process above

Material: T-FZ## Plant: 1000 Usage: 1 Valid from: Today's date

Select: Create variant of

Material: T-F##

Select: Enter Button: Select all Button: Copy

In the Item overview, overwrite item 30 to read:

Item no. Item cat. Component Quantity

30 Stock item T-BZ## 1

Select: Save

1-2 Display your Bills of Material as a BOM group.

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM→ BOM group → Display or Logistics → Central Functions → Engineering→ Bills of material → Bill of material → Material BOM→ BOM Group → Display:

Material: T-F## Plant: 1000 Usage: 1 Valid from: Today's date

Select: Enter

Select: Variants Overview

Select all variants with the left mouse button

Select: Header

Switch between the individual variants using the Next variant and Previous variant buttons:

Field T-F## T-FY## T-FZ##

Internal BOM number

Technical type

BOM number and technical type (V) should be the same.


1-3 Change your BOM group.

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM→ BOM group → Change or Logistics → Central Functions → Engineering→ Bills of material → Bill of material → Material BOM→ BOM Group → Change:

Since the BOM group identifier was not previously maintained, use the following data to access the BOM group. Material: T-F##

Plant: 1000

Usage: 1

Select: Enter

Goto → Header overview

Maintain the BOM group identifier

BOM group: Groups ## Variants

Select: Summarized BOM

Add a new item 090 and set its use for variants T-FY## and T-FZ##.

Item Ict Component Quantity 01 02 03

0090 Stock Item 100-801 1 X X

Select: Save


1-3-1 Verify that the new item appears in each BOM for T-FY## and T-FZ##.

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM→ Display or Logistics → Central Functions → Engineering→ Bills of material → Bill of material → Material BOM→ Display:

Material: T-FY## (first, then use) T-FZ##

Plant: 1000

Usage: 1

Valid from: Today’s date

Select: Enter

Is the red paint now listed as a component for each material? YES

Select: Header

Field Material T-FY## Material T-FZ##

BOM# (internally generated) (same internal number)

Technical Type: V V

BOM Group: Group## Variants Group##Variants


Solutions


Topic: Multiple BOM

1-4 Create alternative BOMs for T-F77## in plant 1000).

1-4-1 Create material T-F77## (##=Group number). Copy from material T-F77.

Logistics → Production → Master Data → Material Master → Material → Create (special) → Finished product

Select: Enter

Select all views except classification and both warehouse management views.

Select: Enter

Review the organizational levels defaulted. Both should be set to

Plant 1000 and Storage location 0002

Select: Enter

Change material description by adding your group number.

Select: Save

1-4-2 Create a Bill of Material

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create: or Logistics → Central functions → Engineering→ Bills of Material → Bill of Material → Material BOM→ Create:

Material: T-F77## Plant: 1000 Usage: 1 Valid from: Today's date

Select: Enter

Add the following components:

Item no. Item cat. Component Quantity

10 Stock item T-B71 0,5 20 Stock item T-B74 1 30 Stock item T-B75 1 Select: Header

BOM Text: ‘Multiple BOM group ##’

Select: Save


1-4-3 From the same screen: Create alternative 2


Select: Copy from

Confirm the message regarding the new alternative being added by selecting Enter

In the Dialog box, accept the default values of the material, plant and usage, but also ADD

Alternative BOM: 1

Select: Enter

Select: Select all Select: Copy

In the item overview, overwrite the component numbers and values to read as follows:

Item no. Item cat. Component Quantity 10 Stock item T-B72 0.3 kg. 20 Stock item T-B74 1.41 kg 30 Stock item T-B75 1 kg

Select: Save

1-4-4 Create alternative 3


Select: Copy from

Confirm the message regarding the new alternative being added by selecting Enter.

In the Dialog box, accept the default values of the material, plant and usage, but also ADD

Alternative BOM: 1

Select: Enter

Select: Select all Select: Copy

In the item overview, overwrite the component numbers and values to read as follows:

Item no. Item cat. Component Quantity 10 Stock item T-B72 0.3 kg. 20 Stock item T-B74 1.41 kg 30 Stock item T-B75 1 kg

Select: Save


1-4-5 Complete header data of all BOM alternatives using the change mode.

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change: or Logistics → Central functions → Engineering→ Bills of Material → Bill of Material → Material BOM→ Change:


Alternative BOM: 1

Select: Enter

Select: Header

Alternative text. 1. Mixed paint

Lot size: from 1 to 100

Select: Save

Repeat these steps for alternatives 2 and 3 using the following text and lot size information.

Alternative2

Alternative text: 2. Mixed paint


Alternative 3

Alternative text: 3. Mixed paint


Remember to save your work.


1-4-6 View all alternatives

Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → BOM group → Change: or Logistics → Central functions → Engineering→ Bills of Material → Bill of Material → Material BOM→ BOM group → Change:

Since the BOM group identifier was not previously maintained, use the following data to access the BOM group.

Material : T-F## Plant: 1000 Usage: 1

Select: Enter

Select: Alternatives Overview

Maintain the BOM group identifier.

BOM group: Group ## Paint

Select each alternative individually

Select: Header

Record the following for each of the variants in this group.

Field Alt.1 Alt.2 Alt.3

Internal BOM number (Internal) (same) (same)

Technical type M M M

Alt. Text 1.Mixed Paint 2.Mixed Paint 3.Mixed Paint

Lot Size Range 1-100 101-200 201-500

1-4-7 Make another change to the BOM group for T-F77## using the Engineering Product Structure feature of R/3.

Logistics → Central functions → Engineering→ Environment → Product Structure

Material: T-F77##

Select: Enter

Drill down on BOMs

Mark: T-F77## 1000 1 01

With the right mouse button, select Change

Select: Enter

Mark alternative BOM 1

Select: Item Overview

Change the quantity of item 30 from 1 to 2.

Select: Save


SAP AG 1999

l RR/3 Organizational Structure Review

n Plant

l PPP Basic Data Elements

n Overview

n R/3 Integration

n R/3 Definition

l RR/3 Cross-Applications Overview

n Document Management

n Classification

Contents:

PP Organization Structures & Basic Data Overview


SAP AG 1999

l Identify the PP organization units

l Describe PP's primary basic data objects

l Explain the R/3 definition of each PP basic dataobject

l Describe the use of:

n Document management and

n Classification functions

l Navigate around the PP menu paths


PP Organization Structures & Basic Data Overview:Course Objectives


SAP AG 1999

l Existing pump basic data will be used tointroduce you to:

n The PP basic data objects

n R/3 terminology

n Document management

n Classification

n R/3 integration

PP Organization Structures & Basic Data Overview:Business Scenario


SAP AG 1999

BOM

Text entry Classification

Material

Work Center

PRTs

Documents

Item 10203040

RoutingOperation10

203040


Basic functionsBasic functions

PP Basic Data and Functions

n Material masters must exist before a bill of material and its components can be defined.

n The components in a bill of material can be assigned to the specific routing operations in the production process in which they are consumed.

n Work centers must be defined before a routing operation can be defined.

n Production Resources/Tools (PRTs) are an optional type of PP basic data that can be assigned to routing operations.

n Documents created in the Document Management System can be specified as components in the bill of material or assigned to routing operations as a document PRT.

n Standard R/3 texts can be created and assigned to PP basic data elements.

n The SAP Classification System can be used to group PP basic data based on user-defined attributes.


SAP AG 1999

Order

Bill of materialBill of material APLAPL

OPR10OPR10

Startdate

Finishdate

t

Cap

acit

y

Machine Staff

Work Center

t t

l Production costsl Production overheads

l Timesl Control datal PRTsl Materiall Quality assurance

10 20 90

OPR 10OPR 20

Capacity planningCapacity planning CostingCosting

SchedulingSchedulingProduction / assemblyProduction / assembly

Basic Data Usage in PP

n Basic data is used to:

� Schedule an order's consumption of materials, use of PRTs, operation times, and so on

� Calculate start and finish dates for an order

� Identify available capacity and expected usage

� Calculate product and production costs.


SAP AG 1999

BOM

Routing

MaterialMaterial


Work CenterWork Center

RoutingRouting

PRTsPRTs

n Material usage (Material number, item category, quantity)

n Storage location (Default value for withdrawal)

n Default value operationn Available capacityn Requirements and scheduling formulasn Activity types and formulas for costing

n Operationsn Standard values

n Procurement type E or Xn MRP, work scheduling,

accounting and costing datan Material status

Basic Data Use in Production Orders

n Input quantity and value

n The material that is to be manufactured has to have in-house production (X,E) available as a procurement type .

n The material status has to be released for production on a cross-plant level (MARA) as well as on a plant level (MARC).

n At least one plant-specific view (MRP and/or work scheduling) has to be maintained for the material, as well as the accounting and costing views.

n Single-level BOMs have to be prepared as BOMs. A special selection procedure chooses the effective BOM.

n Routings have to be prepared as routings (generic). A special selection procedure chooses the effective routing.


SAP AG 1999

Work Center


ExamplesExamples

A work center is a location where a particularoperation is executed.

The following can be defined as work centers:

Automatic lathe 17l Individual work center

Lathe shopl Work center group

Band 9l Production line

P. Smithl Individual person

Pool 12l Group of people

n Work centers are used in task lists (routings, standard networks, inspection plans, maintenance task lists, rough-cut planning profiles) and in orders to identify where the work is going to be performed.

n A work center is a location where the capacity of production resources is consumed by activities performed in the manufacture of products.

n Work centers can be used as capacity collectors for internal and external suppliers (external processing).

n Synonymous terms for work center are machine group and capacity group.


SAP AG 1999

Routing


ExamplesExamples

A routing describes a production process.

10 Pre-assemblyOperation

20 Checking

30 Final assembly

40 Checking

50 Delivery

n The routing defines the operations (sequence of activity) to be performed as well as:

� Where the work is performed

� How long the work should take

� What materials to use for each operation

� What special tools, jigs, etc. are to be used


SAP AG 1999

Production Resources/Tools (PRTs)


PRTs are resources required for production, which are used at different work centers to carry out operations.

PRT categoriesPRT categories Material master

Other

Equipment

Document

ExamplesExamples

Tools

NC programs

Jigs and fixtures

Documents and drawings

n Production Resource/Tools (PRTs) represent a wide variety of items used, but not necessarily consumed during the production process.

n Categories are used in R/3 to distinguish between different types of PRTs.


SAP AG 1999

Document Usage


Documents contain information that is useful either for the person responsible or for transfer between systems

ExamplesExamples

UseUse

AVO 10

AVO 20

Routing BOM

NC program Inspection instr. Brochure Drawing

n Documents are defined separately in the Document Management System.

n Documents can be specified as a component on a bill of material or as a document PRT. Document PRTs can be assigned to an operation in a routing.

n Use of document types in PP basic data definition is authorized in Document Management System customization.

n Course LO975 covers the Document Management System functionality in detail.


SAP AG 1999

l Recognize the organizational units in Logisticsand PP

l Describe the PP basic data elements

l Explain the R/3 definition of each PP basic dataobject

l Describe the document management system


PP Organization Structures & Basic Data Overview:Unit Summary


Exercise Data Explanation of the Icons Used in the Exercises and Solutions

Exercises

Solutions

Course Objectives

Business scenario

Tips & Tricks

Warning or caution message

Data in the Exercises

Type of data Data in the training system Material and BOM P-100

Material and BOM T-F00 to T-F20

Material and BOM T-B00 to T-B20

Material master T-FP##

Work centers T-E, T-F, T-L, T-M, T-P, T-V

Production Resources/Tools PP_FHMM, PP_FHMS

Change master record T-AE##

Activity group SAP_CA_PDM_WORKPREP


Work Center Data Sheet - Page 1 of 2

Parameter Value

Work Center: 206-##

Work center category: LO##

Basic data

Description: Pump Assembly – Group ##

Person responsible: 0##

Usage: All task list types

Standard value key: Normal production (SAP1)

Maintenance rules: Setup time – should be entered

Machine time – must be entered

Labor time – no checking

Efficiency rate: Machine – 90% (090)

Default values

Control key: Choose one of the PP series (P01, PP02 … PP99) control keys. It must allow scheduling, capacity planning, and costing. It must also print time tickets and permit confirmations

Standard text key: Use the one from your exercise „GRT##“.

Unit of measurement: Minute

Reference indicator: Prevent changes to the control key and standard text key values during routing creation or maintenance

Capacities

Capacity category: Machine

Setup and Processing formula: To calculate the capacity requirements, choose the setup (SAP005) and processing(SAP006) formulas.

Capacity: Header Data


Planner Group: 0##

Grouping: 51

Base unit of measure: Hour

Start/Finish time: 07:00/17:00

Length of breaks: 1 Hour

Capacity utilization: 100%

Nos. of individual capacities: 2 machines


Work Center Data Sheet - Page 2 of 2

Parameter Value

Scheduling


Setup and Processing formula: To calculate the duration, choose the setup (SAP001) and processing (SAP002) formulas.

Location group: 0001

Std/min. queue time: 2 hours / 1 hour

Costing

Cost center: 4230 – Assembly Pumps

Activity type: Setup time – 1422

Machine time – 1420

Formula key: To calculate the cost, choose the setup (SAP005) and machine (SAP006) formulas.

Production Process - Data Sheet

Header Data

Material: T-B##

Usage: Production

Status: Creation phase

Planner Group: 0##

Lot Size: 1 to 100 pieces

Primary Operation Data with the Processing Time in Minutes:

Number Work Center

Control Key

Description Setup Machine Labor

10 T-M PP01 (Text proposal from the work center)

3 0 5

20 T-V PP01 Drill holes

10 10 10

30 T-F PP01 Pre-assembly of casing

0 0 5

40 T-F PP01 Final assembly of casing

0 0 5

50 T-F PP99 Deliver to stock 10 0 0


Production Process - Data Sheet

Header Data

Material: T-F##

Usage: Production

Status: Released (general)

Planner Group: 0##

Lot Size: 1 to 100000 pieces

Primary Operation Data for the Standard Sequence with the Processing Time in Minutes:

Number Work Center

Control Key


10 T-M PP01 (Text proposal from the work center)

10 0 0

20 T-E PP01 Pre-assemble pump 30 0 10

30 T-P PP01 Pre-assembly 0 0 5

40 206-## PP01 (Text proposal from the work center)

30 10 0

50 ref. set

T-P PP99 (Text proposal from the work center)

0 0 10

Primary Operation Data for the Parallel Sequence with the Processing Time in Minutes:

Number Work Center

Control Key


10 T-V PP01 Cut raw material 10 10 0

15 T-V PP01 Drill holes

0 0 5

20 T-L PP01 (Text proposal from the work center)

15 5 5


Exercises

Unit: PP Organization Structures & Basic Data Overview

Topic: PP Basic Data Elements


• Navigate around the PP Basic Data menu paths in R/3

• Describe the use of basic data

As a member of the implementation team for a pump manufacturer, you are reviewing the R/3 PP Basic data which already exists within the company.

1-1 Display the material master for product P-100 in plant 1000. Display the basic data 1, classification and work scheduling views.

1-1-1 What is the material type for material P-100? ___________________

1-1-2 What material class does the material P-100 belong to? ______________

1-1-3 What are the pump height and speed of P-100?

_____________ _____________

1-1-4 For material P-100, determine the in-house production time for 100 pieces from the values of the set-up, processing and inter-operation times. _________

1-1-5 Use the classification system to find other products which have the same pump height and speed as the P-100.

1-1-6 Are there other products with the same pump height? __________________

1-2 Change the material BOM for the product T-F## in plant 1000 with the usage 1.

1-2-1 What is the BOM status? _______________________________

1-2-2 When did this BOM become effective? ____________________________

1-2-3 What is the material number of the component for a shaft?

______________________ 1-2-4 Replace item 100-100 with item T-B##.


1-3 Create another R/3 session and display the released (general) routing for product P-100 in plant 1000.

1-3-1 Which usage is permissible for the routing? _____________

1-3-2 On which date did this routing become valid? ________________

1-3-3 What is the labor time for operation 10? ______________

1-3-4 In which work center is operation 0010 carried out and who is responsible for this work center?

___________ ________________________


Solutions

Unit: PP Organization Structures & Basic Data Overview

Topic: PP Basic Data Elements

1-1 Call up the material master for material P-100 with the views: basic data 1, classification and work scheduling, and the organizational level plant 1000.

Logistics → Production → Master data →Material master→ Material → Display → Display current

Material: P-100

Enter

Choose: Basic Data 1

Classification

Work scheduling

Enter

Organization Levels: Plant 1000

Enter

1-1-1 The material category is a finished product. (Top of screen)

Enter

1-1-2 Select the class type 001 to display the classification information. The material class is 100.

1-1-3 The pump height is 10m and the turning speed 1000.

1-1-4 Click on Next screen. The in-house production time is 16.35 days. (Total)

1-1-5 Look for other products in class 100 with a pump height of 10m.

Logistics → Central functions → Classification → Find →Find objects in classes

Class: 100

Enter

Height: 10m

Speed: 1000rpm

Click on Find in initial class.

Yes there are other products.


1-2 Call up the production BOM for the product P-100 in plant 1000 with the usage 1.

Logistics → Production → Master data → Bills of material → Bills of material → Material BOM → Display

1-2-1 Click Header. The status is 1 for active.

1-2-2 The BOM became effective on 08.11.1994.

1-2-3 Click Material item. The material number for the shaft is 100-300.

1-3 Call up the routing for the product P-100 in plant 1000 with a new R/3 session.

System → Create session

Logistics → Production → Master data → Routings → Routings → Standard Routings → Display

Material: P-100

Plant: 1000

Enter

1-3-1 The usage is production production.

HEADER (hat icon)

1-3-2 Look at the date in the Valid from field in the routing header. (Scroll down)

Valid from 11/08/1994

1-3-3 To display the routing operations, choose Operations Select operation 0010 and use the menu path Details → Operation or double-click on the operation number to reveal the operation details. The labor time is 10 minutes.

1-3-4 Place the cursor on the number of the work center (1310) and click Work center. 101 is responsible for the work center.


SAP AG 1999

l Routing structure

l Routing categories

Contents:

Routings - Part 1


SAP AG 1999


l Maintain a routing with operations.

Routings Part 1: Course Objectives


SAP AG 1999

l Your company is introducing a new pump intothe market.

l You are responsible for the routing of thispump.

Routings Part 1: Business scenario


SAP AG 1999

Production / assembly

l Timesl Control data/textsl PRTsl Materiall Quality assurance

Capacity planning

Machines

Cap

acity

Stafft t

Scheduling

Costing

Start date Finish date

10 20 90

l Production costsl Production

overhead costs

Order

DEUTSCHEMARK

DEUTSCHE

MARK

DEUTSCHEMARK

DEUTSCHEMARK

Routing Usage

n A routing is independent of an order. It is copied into the production order when you create a production order.

n The planned time for each operation (standard value) is stored in a routing.

n These standard values are the basis for:

� Lead time scheduling

� Product costing

� Capacity planning


SAP AG 1999

Material componentsMaterial components

PRTPRT

InspInsp. characteristics. characteristics

Trigger pointsTrigger points

Operation 20

MaterialMaterial

Routing groupRouting group

Operation 10

AMaterial

!

ll Work CenterWork Center

ll TextText

ll Control dataControl data

ll TimesTimes

Routing Structure

SequenceSequence

n A routing determines the sequence of individual operations that are necessary to produce a finished product. A routing contains operations and information about the work centers at which the individual operations are to be carried out, as well as standard times.

n Further important information, contained in routings, is for instance, the material components required for an operation as well as the necessary tools, jigs and fixtures (production resources/tools).

n If quality is to be inspected during an operation, you can assign inspection characteristics to the operation in a routing. The starting point for doing so is the characteristic overview.

n You can assign trigger points to operations in routings, so that later in the production order, certain functions are triggered when certain events occur. Examples of such events are a change in status or the confirmation of an operation.


SAP AG 1999

Sequence category

Routing group

Material

Standard sequenceStandard sequence 0000 0000

Parallel sequenceParallel sequence00020002 OPR 70

OPR 60OPR 50OPR 40OPR 30OPR 20OPR 10

OPROPR

7080

AMaterial

RoutingRouting

Group Z 1

10 Wrk ctr 1

20

30

OPR 90OPR 80

OPR 100

Alternative sequenceAlternative sequence00010001

OPR 15OPR 10

OPR 20

Routing

n Routings in a group are used to produce similar materials. You can also combine routings with similar manufacturing procedures in a group.

n An alternative sequence allows you to select alternative operations to a sequence of operations. This could be the case when using different work procedures for various lot sizes or when working around capacity bottlenecks.

n A parallel sequence allows you to process operations concurrently with others. The processing sequence is defined by the branch and return operations.


SAP AG 1999

Inspection plan Q

Standard network 0

Rough-cut planning profile 3

Master recipe 2

Rate routingRef. rate routing

Task list categoryTask list category

RoutingRef. operation set

RM

IndicatorIndicator

N

S

QM

PS

PP-SOP

PP-PI

PP-REM

ApplicationApplication

PP-SFC

10 20 30 40 99

Task List Categories

n Task list types are assigned to different applications, PP-SFC, PP-REM, PP-PI, PP-SOP, PS, QM.

n A routing describes material-related production in Production Planning.

n A reference operation set is not created for a specific material. Reference operation sets can be used as references or as routing templates. They can be created using either internal or external numbers.

n A rate routing describes material-related production within a production line and is used most in repetitive manufacturing.

n A reference rate routing helps you create rate routings.

n A master recipe is used in PP-PI.

n Rough-cut planning profiles are used in Sales and Operation Planning.

n Standard networks are network structures that are independent of a particular project. They are used as a source template, when you create an operative network. This can signif icantly reduce the amount of time you need to create the same activities in different projects.

n An inspection plan is used for carrying out quality inspections and for measures that are relevant to production, for example goods inspection on receipt.


SAP AG 1999

Routing Rate routing

Task list categoryN R

Reference operationset categoryS M

Terms for workcenters

Work centerMachine group Production line

Primaryrouting structure

Multiple operations carriedout in multiple work

centers each with theirown production rate

One production processcarried out on a

production line at oneproduction rate

Primary use in R/3Supports productionorder based

manufacturing

Supports repetitivemanufacturing. Thequantity is based on

planned orders

Routings and Rate Routings

n Routings and rate routings are unique task list types.

n Both routings and rate routings are supported by reference operation sets.

n Routings are used to support production order based manufacturing while rate routings are used to support repetitive manufacturing.


SAP AG 1999

11 11

33

22

22 11

33 11

AMaterial

Group Groupcounter

Plant

22

0202

0101

11 0101

0202

Material Routing Assignment

n A material can be assigned to different routings. The routings in a group are differentiated using the group counter. Routings are identified by their group and group counter values.

n Groups contain routings that have similar production processes. For instance you can have different routings for different lot sizes; these could be in one group.

n One routing can be used to produce several materials. For instance left-hand doors and right-hand doors can be produced using the same routing. You can even assign these different materials to different plants.


SAP AG 1999

PRTsPRTsWork CenterWork CenterMaterial masterMaterial master

ProfileProfile

l Control keyl Standard text keyl Unit of measurel formulasl Scheduling data

l Control keyl Standard text keyl Standard value checkl Unit of measure for

standard valuesl Activity typesl Wage typel Wage groupl No. of time ticketsl Suitabilityl Setup type key

l Descriptionl Base unit of

measurel Planner group

l Plantl Routing unit of

measurel Usel Statusl Operation increment

Referencexx

x

xx

x

xx

Referencex

x

x

x

x

Origin of Default Values in Routings

n The default values from the work center can be references. You can also specify entry rules for standard values in a routing.

n You can specify default values in a profile for each routing usage.


SAP AG 1999


l Create a routing with a simple sequence ofoperations

Routings Part 1: Summary


Exercises

Unit: Routings - Part 1

Topic: Creating a Routing


• Create a simple routing

You are responsible for the routing definition of an assembly and of a new pump.

1-1 Create a production routing for the new assembly T-B## in plant 1000 which is valid from today’s date. The routing is unreleased and is valid for production quantities of 1 to 100 only.

This product can be produced in 5 steps. For the routing, use the work centers and operation data from the data sheet that the project team created for this production process.

On the operation overview, enter the work centers and the description. Respond to the dialog box “Copy standard text” with no.

Answer exercise questions 1-1-1 through 1-1-2 before saving the routing.

1-1-1 What is the base quantity and operation unit for operation 10 and how does it relate to the standard values?

____________________________________________________

1-1-2 What are the task list group and group counter?

____________________

1-1-3 Save your routing.


1-2 Display the routing for the new assembly T-B##.

1-2-1 What are the task list group number and group counter?

_____________________

1-2-2 When was the routing created and by whom?

______________________________________

1-2-3 What are the effectivity dates for the routing?

______________________________________

1-2-4 What are the effectivity dates for operation 20?

______________________________________


Solutions


Topic: Creating a Routing

1-1 Create a routing with the data sheet for material T-B##.

Logistics → Production → Master data → Routings → Routings → Routing → Create

Material: T-B##

Plant: 1000

Enter

Choose Operations or Goto → Operation overview to enter your operation data.

Select the operations from the operation overview and choose Detail → Operation detail to enter the standard values. To enter the standard values in different operations, click on Next operation.

1-1-1 1 piece. The standard values entered are the setup and labor time required to manufacture one casing.

Back arrow

Select operation 010 then Details → Operation

1-1-2 None, the routing is blank The group counter is 1.

Detail → Header (hat icon)

1-2 Display the routing.

Logistics → Production → Master data → Routings → Routings → Routings → Display

1-2-1 Click Task list header.

1-2-2 Scroll to the administrative data.

1-2-4 Select Operations Overview and choose the operation detail for operation 20 by double clicking. Scroll to the operation administrative data.


SAP AG 1999

l System settings

l Work center categories

l Default values for routing operations

l Links with work centers

l Work Center Hierarchy

l Evaluation program

Contents:

Work Center


SAP AG 1999

l Identify which work center data is relevant forroutings

l Define default values for work centers

l Configure work centers


Work Centers: Course Objectives


SAP AG 1999

l Your company wants to reorganize its work centers

l You are responsible for setting up and maintainingthe work centers.

Work Centers: Business scenario


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Available capacityl Capacities (machine, personnel, set-

up,...)l Available capacity cycle (normal

working, reduced working from/to,...)l Shift sequencesl Shifts

Schedulingl Formulasl Wait times

l Descriptionl Locationl Hierarchy

Costingl Cost centerl Activity types

Default values

Work Center

n Work centers determine the place where the operation is to be executed.

n Work center master data contains default values that are copied or referenced in operations when you create routings.

n Work center master data contains costing data necessary for costing operations.

n Work center master data contains the scheduling and capacity data required for lead time scheduling and capacity planning.


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l Cost centerl Activity typesl Formula keys

l Scheduling basisl Wait and move timesl Formula keys

l Available capacityl Formula keys

l Name and descriptionl Standard value key

Assignment

Scheduling

Capacity

Default values

Basic data

Costing and HumanCosting and HumanResources dataResources data

Scheduling dataScheduling data

Capacity dataCapacity data

Default values for Default values for routingrouting


l Control keyl Standard text keyl Wage data

Work Center Data

n A work center contains several groups of data that you can enter on various screens.

n Default values are copied to the routing. You use the reference indicator to specify whether a default value can be changed in the routing.


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Screen seq. control / Field selection Change documents Task list usageWork center categories

D

Task list usageO

Standard value keyD

Screen sequence control / field selection controlD

OLocations, location groups, move time matrix

Set up default / reference work centersO

Sequence for Customizing Work Centers

n Legend:

O = Optional activity (can)



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Screen groupsScreen groups

Field displayField display

Entry field - optionalEntry field - mandatoryDisplay fieldHidden fieldHighlighted

Modifiable fieldsModifiable fields

Fields for work centerscreen group

For example,efficiency rate key

Object (value) in modifiable fields

General work center cat.

InfluencingInfluencing

ORORl Basic data

l Default values

l Scheduling

l Capacity

Field Selection Work Center

n Work center fields are grouped together in screen groups .

n For each screen group, the modifiable fields are predefined by SAP.

n Attributes (mandatory entry, display and so on.) can be switched on or off for each field.

n Additionally the field settings can be controlled by the work center category. You use the modifiable fields button to do this. The only dependency for the work center is the work center category.

n You can transport and release settings for field selections.

n You can also define the sequence of the screen groups (menu option: set up work center sequence).


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ProductionProduction

Repetitive manufacturingRepetitive manufacturing

Capacity planningCapacity planning

RoutingRouting

RoutingRouting

Group Z 1

10 Wrk ctr 1

20

30

SOPSOP

StatisticsStatisticsQualityQuality

managementmanagement


Work Center Usages

n Work centers are used in various applications for various purposes.

n You assign work centers to particular work center categories depending on their function.

n The work center category mainly controls the field and screen selection for work centers.

n Usually particular work center categories are used for particular purposes, such as in a routing or a network. However there are no fixed assignments.

n In Customizing, you can set default values per work center category and per plant as well as the screen sequence.


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(Origin 2)SAP_02 machine time

Formula parameterFormula parameter


RoutingRouting

Standard value key

Set-up time

Machine timeSAP_02 machine time

Standard value keyStandard value key

Standard Value Key

SAP_01 Set up time

Operation 20Operation 20

n You can use the standard value key to assign a meaning and a dimension to the six possible standard values of origin 2.


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Order header

OperationsOperations

Material componentsMaterial components

Production Resources/ToolsProduction Resources/Tools

Kosten PlanSollIst

Kosten PlanSollIst

205 0

100

Basic dataStandard value keyStandard value validationPerformance effic. rate keyBackflushing

Control keyStandard text keySuitabilitySetup type keyWage typeWage groupNo. of time ticketsNo. of confirmation slipsPrint shop floor papersUnits of measure standard values

Activity types

RoutingRoutingDefault values

Cost centerassignment


Default Values in Work Centers

n The work center contains default values that are copied when you create an operation and that can be changed if necessary in the operation.

n If the default values are marked as a reference in the work center then you cannot make a change in the operation.

n When setting up PP you must make sure that as much data as possible is defined in work center maintenance.

n This default data is copied into routings and/or production orders.

n This default data is saved partly in various screens in the work center.

n Activity types are proposed from the cost center assignment screen.


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XXX

X

XXXX

X

XXXX

X

X

X

X

X

ControlControl OperationOperation Sub-operationSub-operation

l Schedulingl Capacity planningl Inspection characteristics

l Automatic withdrawal(from confirmation)

l Print time ticketsl Reworkl Print confirmation slipl Print operation

l Costing

l Confirmations:- Mandatory- Possible- Forbidden- Milestones

l External processing

Operation Control Key

n The operation control key is used by the system to control the maintenance of individual operations.


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ApplicationApplication

Frequently repeateddescription of aproduction cycle

A template is a standard text


Work Center(default)

Workoperation

RoutingRouting

Group Z 1

10 Wrk ctr 1

20

30

Standard Text for Operations

UseUse

n You maintain standard texts under Routings-Extras. It is identified by the standard text key.

n You can enter the standard text key in the work center. When you use the work center in a routing, the standard text is copied or referenced in the operation.


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Work Center Links

PositionPosition

Cost centerCost center

......QualificationsQualifications

......PeoplePeople

n You can assign a work center to only one cost center. However, you can assign a work center to several work center hierarchies using a graphic.

n You can only assign people, qualifications and positions if the Personnel Planning and Development System (PD) in SAP's HR application has been implemented.


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Costs for internal activity

lDefault value keyl Formula constantsl Formula keys

Cost center

Standard value key Formula constants

Formula keys

Production Costing

Work centersWork centers

Cost rateCost rate

Activity types

Formula

Operations Work centers

Standard values

RoutingRouting

n Work centers are assigned to a cost center for costing operations.

n A cost center can contain several work centers.

n You must enter the activity types relevant to costing at a work center in the cost center. An activity type master must be created for the activity types used.

n The activity types maintained in the work center are used as default values for the operation. If the reference indicator has not been set for activity types in the work center, you can change it in the operations.


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PRODUCTION TURNING

Milling shop Mech. workshop

LathesLathesNC-Lathes

Lathesin plant 2

Lathe shop

Production Plant 1

Machine t

Cap

acity

Lathesin the concern

Machine t

Cap

acity

Lathesin plant 3

Lathesin the laboratory

Machine t

Cap

acity

Machine t

Cap

acity

Machine t

Cap

acity

Work Center Hierarchy

Machine t

Cap

acity

n Work centers at a plant can be arranged in work center hierarchies. There can be any number of levels to the hierarchy.

n Work center hierarchies serve to cumulate available capacities and capacity requirements in capacity planning.

n A work center can be assigned to several hierarchies.


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Work center/CapacityWork center/Capacity

l Replace work centers with changes to the default values, standard values and activity types

l List of work centersl Cost center assignmentsl Work center capacitiesl Work center hierarchiesl Work center/capacity

usagel Change documents

Mass changesMass changes EvaluationsEvaluations

Work Centers / Capacities - Reports


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l Create a work center with the relevant data foroperations and configure a work center

Work Centers: Summary


Exercises

Unit: Work Center

Topics:

• Define work center categories

• Create standard texts

• Create a work center


• Create a standard text

• Set up a work center category

• Create and change a work center

Two new machines have been purchased to support the assembly process for the new pump.

You are responsible for the definition of a new work center representing the two new machines.

1-1 Define a standard text for the description of an operation as the default text for the new work center.

1-1-1 Create standard text key GRT## with a description indicating the text as Group ##’s assembly instructions. Enter Complete the pump assembly as the long text. Save.

1-2 Create a new work center category for your business function.

1-2-1 The work center category number should be LO## and the description should be Group ##. Save.

1-2-2 The work center category should be set up for the task list usage: Routings for production. Save.

1-2-3 For your work center category, determine the screen selection in the sequence: basic data, default values, capacities, scheduling and costing, with the key LO##. Save.

1-2-4 Assign the created screen sequence and the field selection 0001 to your work center category.


1-3 Create a work center for the two identical new machines, for the work center category defined in exercise 1-2. To maintain the work center, use the data sheet that the project team provided for this machine. Save.

In order to maintain the individual tab pages (screen sequences), click Next screen.

1-3-1 What impact will the labor efficiency rate have on the labor time entered for operations using this work center?

______________________________________________________

______________________________________________________

1-3-2 Can operations using this work center be defined without entering a Setup time?

______________________________________________________

1-3-3 Can a work center with only the basic data and default value tab pages defined, be used to define routing operations?

______________________________________________________

1-3-4 Why is the assignment of a capacity category on the scheduling view important?

______________________________________________________

______________________________________________________

1-3-5 What is determined by location group?

______________________________________________________

______________________________________________________

1-3-6 Why is the activity type so important?

______________________________________________________


Solutions

Unit: Work Center

Topics:

• Define work center categories

• Create standard texts

• Create a work center

1-1 Creating standard text GRT##

Logistics → Production → Master data → Work centers → Extras → Standard texts

Std. text key: GRT##

Description: Group ## Assembly instructions

Select : create

Enter text

Save

1-2 Creating work center category LO##.

Tools→ Accelerated SAP → Customizing → Edit project → SAP Reference-IMG

1-2-1 Creating a work center category

Production → Basic data → Work center → General data → Define work center category

New Entries button

1-2-2 Double click Application (in dialog structure).

Select category LO##

Double click Application again.

Select: New entries

APPL: “P” (routings)

Save

Up arrow

1-2-3 Determine the screen for the work center category by deleting the screens that are not necessary.

Production → Basic data → Work center → Set up work center screen sequence

Enter: LO##


1-2-4 Define work center category

Field selection: 0001

1-3 Creating a work center according to the data sheet.

Logistics → Production → Master Data → Work Centers → Work Center → Create

1-3-2 The machine standard time entered is divided by 90% because the real operation time is less than the standard value entered on the routing.

1-3-3 Yes, but a warning message will appear prompting entry of a setup time.

1-3-4 Yes.

1-3-5 It defines which capacity category header parameters are used in the calculation of schedules. For example, the machine capacity category defines what the working day is, and that this work center is available for production each workday between 0700 and 1700 hours.

1-3-6 Move Time. The actual move time value is defined in a move time matrix. The actual move time is the value associated with the location group of the work center on an operation, as it relates to the location group of the work center on the next operation of a routing.

1-3-7 The activity type contains the cost center’s price for each activity to be performed in the work center.


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l Customizing steps for routings

l PRT categories

l Alternative and parallel sequences

l Sub-operation

l Reference operation set

Contents:

Routings - Part 2


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l Carry out the system settings for routingadministration

l Create and use a production resources/tools(PRT) in a routing

l Create alternative and parallel sequences

l Create and use a reference operation set in arouting

At the conclusion of this unit, you will beable to:

Routings Part 2: Course Objectives


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l In the project team you are responsible for routingadministration

l You are responsible for testing the following routingfunctions:

n Creating and using production resources/tools (PRT)

n Alternative and parallel sequences in routings

n Standard procedures using reference operation sets

Routings Part 2: Business scenario


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Routing: Task list type/material type

Task list usage

Task list status

R.-operation:Operation control key

Setup type, setup group

User-specific settings Wage type, wage groups, suitability (qualification)

? ?

D

D

D

M

O

O

Standard value determination type

Relevancy to costingCosting 09,- 11,- 64,-

O

O

Sequence for Customizing Routings 1

n Legend:

M = Mandatory activity (must)




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General: Object overviews

Field selection

User-defined fields

D

O

D

User-specific settings

Set up default valuesO

Sequence for Customizing Routings 2

n Legend:




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DocumentDocumentPRT masterPRT masterMaterial masterMaterial master EquipmentEquipment

ProcurementInventorySales and distribution

Plant maintenance

ClassificationDocument assignment

ConfigurationSchedulingQuantity calculationConsumption (usage value)

üüü

üüüü

üü

ü

üü

ü

üü

üüüü

üü

üüüü

üü

üüü

PRT Categories

n Production resources/tools (PRTs) are required to carry out an operation.

n In the SAP System, you can assign various PRT categories to an operation in a routing or a production order.

n The PRT category is determined by the requirements of a PRT and its reference to a particular object (material, equipment, and so on).


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OPR 10

OPR 20

OPR 30

PRT 1

PRT 2


10 Wrk ctr 1

20

30

Production Resources/Tools

n You can assign production resources/tools (PRTs) to each operation.

n The PRT must be identified by a material master or a PRT master.


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Set up machineMill pump casingTurn pump casingDeburr pump casing

y

y

n

nnn

y

y

n

y

yyy

y

y

n

y

yyy

y

Operation no. Description

Cut Material10

20 Machine pump casing

30 Inspect

20 / 1020 / 2020 / 3020 / 40

Control key

Sched. Cap. Cost.

Sub-Operation

n Sub-operations are used to carry out more detailed planning or costing for an operation.

n For example, sub-operations are used in the company for production islands.

� In this slide, operation 20 is responsible for compliance with the production schedule.

� Sub-operations 20/10 to 20/40 are used for exact capacity planning and costing

n The control key has an important influence on this process. It is important to make sure when using sub-operations that costs and capacity requirements are not calculated twice.

n Scheduling always takes place at operation level.

n The standard values of the sub-operations can be cumulated to the appropriate operation according to the dimension and the unit of measure.


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QueueQueue WaitWait

Finish reference to offset

ExecutionExecution

10 3020

SS

20/1020/10

20/20

Start referenceto offset

Start referenceto offset

20/30

BS BFSS SF

Finish reference

MoveMove

Scheduling Sub-Operations

n The dates of the sub-operations are determined by entering a start and finish reference to an operation segment along with an offset value.

n The reference dates for the sta rt and finish of a sub-operation are:

� Start date for setup

� Start date for processing

� Start date for teardown

� Start date for execution

� Start date for wait

� Finish date for wait

n If an operation is divided into sequenced sub-operations, the standard values for the sub-operations can be cumulated as the operations standard values. If an operation is divided into sub-operations that are processed in parallel, the standard values of the sub-operations should not be cumulated as the operation's standard value. If cumulated, the operations standard values could be substantially overstated.

n Example: Start reference: Start date for processing offset value: 5- (5 minus) hours.This definition tells the system to schedule the sub-operation to begin 5 hours before the processing start date of the operation to which the sub-operation belongs.


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Standard Standard sequence 0000sequence 0000

OPR 10

OPR 20

OPR 30

OPR 40

OPR 50

Alternative Alternative Sequence Sequence 00020002

20

25

30

Alternative Alternative Sequence Sequence 00010001

15

20

25

30

10

Sequences in Routings

n Alternative sequences are linked to the standard sequence.

n Branch operations in the standard sequence are ignored in the procedure.


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Parallel Sequences

20 25 30

Operation 20 30Operation 10

20 30

40 50 60

45 55

IIIII

IIIIIIIII

IIIIIIIII = Sequence float

IIIIIIIII

Parallel sequence 1

Parallel sequence 2

Parallel sequence 3

n Parallel sequences are special types of overlapping operations.

n Application: In mechanical engineering for assemblies with production of individual components. For instance you can use parallel sequences to assemble several small assemblies required in a BOM.

In the chemicals industry for analytical processes that occur parallel to the production process.

n An alignment key defines the start of the individual parallel sequences and consequently the position of the sequence float.


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Routing

10

20

30

Operation Detail Screen

Field Key: 0000001

Prompts appearance of additional:

Text fields Date fields

Quantity fields Value fields

Check boxes

Each field's name is user-defined

User-Defined Fields in Operations

n User-defined field keys can be used to add data entry fields to the operation detail screen.

n Field keys are capable of supporting:

Quantity Field type

2 Text (20 characters)

2 Text (10 characters)

2 Date

2 Quantity and unit of measure

2 Value and/or currency

2 Check boxes

n In Customizing, users create a field key name and then enter a field name for each additional field to be displayed.

n The quantity fields can be used as formula parameters in formulas for calculating execution time and capacity requirements. These fields can also be used in product costing.


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Reference operation set

Inspect10

Assemble10

20

30

Reference Operation Set


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Inspect10

Routing

Operation created manually10Assemble10

20

30



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Inspect10

Routing

Operation created manually

Operations with reference to reference operation set 'Assembly'

10

20

30

40

Assemble10

20

30

Assemble



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Inspect10

Routing



Reference 'Check'

60 Operation created manually

10

20

30

40

50

Assemble10

20

30

Inspect

Assemble



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Inspect10

Routing



Reference 'Check'


10

20

30

40

50

Assemble10

20

30

Inspect

Assemble

Reference 'Check'70

Inspect



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Inspect10

Routing



Reference 'Check'


Reference 'Check'70

10

20

30

40

50

Assemble10

20

30

Inspect

Assemble

Inspect


n A reference operation set is used to describe a frequently used sequence of operations. It can be used either as a reference or as a template when you create a routing.

n A reference operation set does not allow parallel and alternative sequences.

n You can assign a material to a reference operation set.

n You can use the "copy from" function to copy a reference operation set from a routing or a reference operation set. If you copy from a routing only the basic sequence is copied. If you copy from a reference operation set there is no reference.

n You cannot copy from a routing that has a reference to a reference operation set.

n You can only create a reference to an operation set in the operation overview of the routing.


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l Carry out the system settings for routingadministration

l Maintain a routing with PRTs as well as alternativeand parallel sequences

l Create and use reference operation sets inroutings

Routings Part 2: Summary


Exercises


Topics:

• Create and use a reference operation set

• Create parallel sequences

• Assign production resources/tools


• Create a reference operation set and include it in a routing.

• Apply parallel sequences.

• Assign production resources/tools to an operation.

You are responsible for the definition of manufacturing data used to support the production of the new pump. These definitions include:

• Identifying a gauge to be used during final assembly inspection.

• Creating frequently used operations as reference operation sets

• Creating the routing for the new pump

1-1 You can define standard processes in the form of a reference operation set for the final assembly of the pump.

1-1-1 Create a reference operation set for the final assembly. The reference operation set should have the status released (general) and be used for production. Planner group 0## is responsible. Enter Checking group ## as a short text.

Do not forget to enter your planner group and the short text. It helps you find your reference operation set using the internal number assignment.

1-1-2 The reference operation set consists of one operation performed in work center T-P. You copy the control key and the standard text key with the operation description from the work center. The standard value for personnel is 10 minutes.


1-2 Create a routing for the new pump. Use the data sheet for material T-F## for the task list header data and the operations. The pump can be produced in a total of 8 steps, 5 of which in the standard sequence and 3 in a parallel sequence.

1-2-1 First of all, create the standard sequence for pump T-F##. Create operation 50 for the final assembly with the help of the reference operation set from exercise 1-1. However, this operation can not be changed in the routing.

First of all, enter operations 10 through 40 and each time, then respond to the Copy standard text dialog box with No.

1-2-2 After you have saved your routing you notice that to check the inspection instruction in operation 50 you need an inspection gauge. Assign the inspection gauge with the material master PP-FHMM to this operation, and be aware of the mass changes to the operation data.

1-2-3 Using the data sheet, create the parallel sequence to pump T-F## in order to process a sheet of metal. The parallel sequence has to be checked with operation 30.

1-2-4 Look at the sequence of your routing on the graphical interfaces.

1-3 Save your routing and look at the control key in operation 40 of the standard sequence. Why are you unable to change the control key for this operation?

____________________________________________________________


Solutions


Topics:

• Create and use a reference operation set

• Create parallel sequences

• Assign production resources/tools

1-1 Creating a reference operation set.

1-1-1 Define a standard process.

Logistics → Production → Master data → Routings → Routings → Ref. Operation sets → Create

Enter

Short text: Checking group ##

Usage: 1 (production)

Status: 4 (released general)

Planner Group: 0##

Lot size unit of measure: PC

1-1-2 Operations button

Work center: T-P

Select operation: 010

Details → Operation

Labor: 10 mins

Back arrow

Save


1-2 Creating a routing.

Logistics → Production → Master data → Routings → Routings → Routing → Create

1-2-1 Operations button to enter operations 10 through 40. Use the menu path to include the reference operation set.

Extras → Reference → Create

1-2-2 Assign the production resources/tools to the reference operation set.

Logistics → Production → Master data → Routings → Routings → Ref. Operation Sets → Change

Enter

Group: Enter the group no. of your group’s reference set.

Enter

Select: operation 10

Goto → Prod resources/tools

Material: PP FHMM

Enter

Save

1-2-3 Creating a parallel sequence.

Logistics → Production → Master data → Routings → Routings → Standard Routing → Change

Goto → Sequence overview and click New Entries.

Choose: Parallel

As a reference choose branch operation 10 and return operation 20. To maintain the operations, click Operations overview. You are already familiar with the procedure for entering an operation text.

1-2-4 Switch to the sequence overview and choose Goto → Graphic → Operation graphic.

1-3 In work center 206-## the reference indicator has been set for the control key. Therefore it is not possible to overwrite the control key in the routing.


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l Material component assignment

l Alternative manufacturing procedure

l Scrap

l Object overviews and evaluations

l Mass changes

l Changes with history

Contents:

Work Scheduling in Detail


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l Describe the types of scrap supported in R/3

l Make evaluations and mass changes

l Document changes using a change masterrecord

At the conclusion of this unit, you will beable to:

Work Scheduling in Detail: Unit Objectives


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l You are responsible for the correct provisionof material components for the operation andthen have to assign these components tooperations and if necessary adjust the BOMs.

l Your company produces products withdifferent order lots and also with otherproduction procedures. You thereforemaintain additional routing alternatives forthese products.

Work Scheduling: Business Scenario 1


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l For a part of the product, the company needs toplan for scrap. You are responsible for definingthe scrap calculation values.

l In your company, information is frequentlyrequired about objects used in BOMs androutings. You ensure that the necessary reportsare available.

l Your company has to document the changes inits BOMs and routings. You are responsible forensuring changes are documented with history.

Work Scheduling in Detail Business Scenario 2


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Item 10

Item 20

Item 30

OPR 10

OPR 20

OPR 30

AMaterial


BMaterial


Item 10

Item 20


10 Wrk ctr 1

20

30

Material Assignment

n You can assign material components to operations by displaying the material component overview. You can use various criteria to filter or sort the material components .

n Other functions include:

� New assignment

� Deleting and reassigning material assignments

� Navigating between operations if more than one has been selected.

n You can maintain BOMs completely without having to leave routing maintenance.


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Increases required quantity of all components

Maintained in material master of assembly

Overrides assembly scrap

Maintained in the BOM

Increases required quantity of a component

Maintained in BOM or material master of component

Reduces operation quantity of subsequent operationsMaintained in routing

Assembly ScrapAssembly Scrap

Component ScrapComponent Scrap

Operation Scrap, Net IndicatorOperation Scrap, Net Indicator

Operation ScrapOperation Scrap

Scrap Categories and Their Effects

n Scrap is used to calculate material requirements and product costing.

n Component scrap is used to plan for the loss of individual components during the manufacturing process. During BOM explosion the system increases only the component quantity of the calculated scrap quantity. Example: A component is broken regularly during the manufacturing process.

n Assembly scrap is only used when the material is an assembly. Reasons for the assembly scrap include breakage during movement to next operations, inspection test failure, manufacturing environment conditions (heat, cold, humidity), and so on. In the MRP, the system increases the material requirement for all components contained in the assembly to that for each component in the calculated scrap quantity.

n Operation scrap in the BOM identifies how much of the end item is lost during production of each component The specification replaces the estimated assembly scrap for the high quality materials and allows for more precise MRP. The net indicator ensures that the component operation scrap is calculated without taking into account the assembly scrap (net input quantity). You have to set the indicator if no operation scrap was maintained and the assembly scrap was not taken into account.

n Operation scrap in the operation results in a fall in quantity in the next operation and is taken into consideration during scheduling and costing. This value can be accumulated for all operations and updated on the material master as the product's assembly scrap.


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5%

5%

7%

Housing for pumpHousing for pump

3%

Material master /BOM

Routing

11.11%Material masterAssembly scrap

Gasket

Screws

Turnblank

Drillholes

Installhousing

2%Blank

0%

10 pieces per hour

10 pieces per hour

5 pieces per hour

1010

2020

3030

Planned Scrap - Example

n Assembly scrap calculation from operation scrap entered on the routing. Assembly scrap equals 11.11%. Formula: total scrap quantity (10) divided by total yield quantity (90)

Operation Nr. Scrap Start quantity Scrap quantity Operation yield

10 5% 100 5 95

20 5% 95 5 90

n Based on the component scrap and operation scrap values defined on the BOM and routing, the system calculates the following planned component and production quantities:

Required Assembly Component BOM Oper. Required Material Operation scrap % scrap % scrap % Net Quantity

Blank 10 12% 2% 0% N 115

Screws 30 12% 7% 0% Y 107

Gasket 30 12% 3% 0% Y 103

n Execution time:

Operation Production quantity Time target Required time h

10 112 10 h 11.2

20 106 10 h 10.6

30 101 5 h 20.2


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RoutingRouting

l Replace work centerl Replace reference

operation setl Replace PRT

l Work center usagel Reference operation set

usagel PRT usagel Routing changesl Change documents

Mass changesMass changes EvaluationsEvaluations

Routings / Reference Operation Sets - Reports


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Mass Replacement of Routing Data

inselected

Work Center


PRT

Work Center


PRT

OldOld NewNew

RoutingsRoutings

n You can use the replace function to make mass changes to the following:

� Work centers

� PRTs and

� Reference operation sets


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l Describe the types of scrap supported in R/3

l Make evaluations and mass changes

l Document changes using a change masterrecord

Work Scheduling: Summary


Exercises

Unit: Work Scheduling in Detail

Topics:

• The assignment of material components

• Where-used lists

• Changes with history


• Assign and process material components

• Carry out evaluations

• Display object overviews

You are responsible for the creation and optimization of the production processes.

1-1 To produce a pump T-F##, sheet metal 100-700 is needed in the parallel sequence. You have to cut this sheet metal along with its trimming allowance (therefore making it larger than the final size).

1-1-1 Assign component 100-700 to operation 010 sequence 1.

1-1-2 In the input screen, enter the dimensions 1000 mm x 1000 mm.

1-2 The necessary inspections for the pump have changed and you have to adjust these with the inspection gauge. You ensure that this inspection gauge is not being used in other routings and execute a where-used list for the production resources/tools (PRT) PP-FHMM.


1-3 The where-used list shows that this PRT is being used in other products. You decide to use another PRT in your routing. This routing change has to be documented.

1-3-1 Use the change master record T-AE## to replace PRT PP-FHMM with the miscellaneous type of PRT PP-FHMS.

Change the PRT in the reference operation set by adding the miscellaneous type of PRT and deleting PP-FHMM.

1-4 You want to get a complete overview, on today’s date, of all sequences, operations, PRTs and material components for the pump.

1-4-1 Call up the object overview of pump T-F## that meets these requirements.

1-4-2 Which PRT is in operation 50?

1-4-3 Why are not all the BOM components displayed?

______________________________________________________

1-4-4 What happens to these components in the production order?

______________________________________________________

1-5 Repeat looking at the object overview of the pump T-F## using key date today’s date + 2 weeks.

1-5-1 Which PRT is in operation 050?_________________________________ Why?______________________________________________________


Solutions

Unit: Work Scheduling in Detail

Topics:

• The assignment of material components

• Where-used lists

• Changes with history

1-1 Logistics → Production → Master Data → Routings → Standard routings → Change

Material: T-F##

Plant: 1000

Enter

Click on Comp.Assignment to switch from the operation overview to the material component overview.

1-1-1 Assign the variable size item 100-700 to operation 10 in sequence 1 by clicking on New assignment and in the dialog box that appears, click on oper./act. list.

1-1-2 Select the assigned component and choose Detail → Mat.Components → General data.

1-2 Displaying PRT usage.

Logistics → Production → Master data → Routings→ Reporting → Where-used list → Prod resources/tools

In the initial screen, under task list category, you have to enter the task list categories N through to S in addition to the PRT number. Choose the overview variant L00000000260.

Execute


1-3 Exchanging the production resources/tools

1-3-1 Use the change master to call up the reference operation set in the change mode. Click PRT and then Other, to enter the PRT. Delete the PRT that is no longer effective.

Logistics → Production → Master Data → Routings → Routings → Reference operation sets → Change

Group: The reference operation set for your group

Change No.: T-AE##

Enter

Select: operation 10

Select: PRT overview

Select: PP FHMM

Delete

Choose: others (miscellaneous)

PRT: PP FHMS

Choose: Insert line

Save

1-4-1 For the object overview, select overview variant 000000000004.

1-4-2 PP-FHMM

Logistics → Production →Master data → Routings → Routings → Standard Routing → Change→ Goto → Object overview

1-4-3 Only those components that have also been assigned in the routing are displayed.

1-4-4 The unassigned components of the first operation in the order are assigned in the production order.

1-5-1 PP FHMS. Because the overview is reviewed after the effective date of the change master


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l System settings

l Time elements and their origins

l Scheduling a routing

l Updating scheduling results in the material master

Contents:

Scheduling


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l Set the system for scheduling

l Maintain working times in the work center

l Maintain the calendar

l Update the in-house production time of therouting in the material master


Scheduling: Topic Objectives


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l As a member of the project team you areresponsible for feasible and exact schedulingof the company's products.

l To schedule products properly you mustunderstand how:

n Workdays and work time are maintained

n Formulas are set up

n The in-house production time is maintained in thematerial master

n Reduction measures are prepared

Scheduling: Business Scenario


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Lead time schedulingLead time scheduling Order headerOrder header

Operations

Material components

Production Resources/Tools

Kosten Plan

Sol l

I s t

2050

100

l Used for orders and routingsl Exact to the secondl Based on basic dates

l Determines target dates (scheduled dates)

l Based on in-house production time or operationl Capacity requirements calculated

MRPmanually

Target start dateTarget finish date

l Separate scheduling of planned orders

Planned finish datePlanned start dateCreation date

Material Requirements Planning

tPeriod

l Exact to the dayl Basic dates calculated

l Basis for in-house production or replenishment timel Improved performancel No calculation of capacity requirements

Scheduling in Production Planning

n Production planning has two types of scheduling that are implemented in different ways.

n To guarantee smooth materials requirement planning, it is absolutely necessary to schedule a routing and to update the material master with the scheduling results.

n If materials requirements planning (MRP) is carried out without scheduling, as in the top half of the graphic, no capacity requirements are determined for the production order either.

n Production orders are always scheduled using lead time scheduling for the operations.

n You can also use lead time scheduling to determine capacity requirements for planned orders in MRP.

n A production order always contains both sets of dates (basic dates and scheduled dates).

n Scheduled dates are relevant for production.


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Execution timeFloat beforeproduction

Float afterproduction

In-house production timesIn-house production times

Backwards schedulingRequirements datefor product

BS BF

In-house production times

Time

Variable-size part

Planned Delivery Time

Assembly

BF BF

Product

Scheduling: Calculation of Basic Order Dates

BS BS

n Material Requirements Planning explodes a material's BOM, generates planned orders for the components to be procured and calculates basic order dates.

n Basic order dates (planned dates) are calculated using the in-house production time or the planned delivery time in the material master.

n The in-house production time for a material can be calculated using lead time scheduling of a routing without an order and is then copied to the material master.


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BS BF

10 20 30 40 50

Float beforeproduction

Lead time scheduling using routing

In-house production time smaller

In-house production time greater than in routing

In-house production time from material master


Requirements date

Incorrect in-house production time in material masterIncorrect in-house production time in material master

Calculation of production order datesCalculation of production order dates

Calculation of planned datesCalculation of planned dates

Scheduling: In-House Production Time

n You maintain the in-house production time in the material master.

n To calculate basic dates correctly in requirements planning, it is very important that the in-house production time in the material master agrees with the results of lead time scheduling using a routing.


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RoutingRouting

Default valuesStandard value key

Capacity planning

Available capacityformulas

Cost center

Activity typesformulas

Working timeformulas

Scheduling

Work Center Integration

n The standard value key and formula keys in the work center form the basis for scheduling, capacity planning and costing.


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Capacity categories and capacities

Shifts and shift sequences

Formulas and formula parameters

Scheduling types

Scheduling parameters and levels

O

O

O

D

M

OCumulation of available capacity (period pattern key)

Configuration Sequence for Formulas, Capacitiesand Scheduling

n Legend:

M = Mandatory activity (must)




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Work CenterWork Center Capacity categoriesCapacity categories

Cap.Cap.

Energy

Machine

Move

Staff

Storage

Waste

Pooled capacityPooled capacity


Cap.Cap.MachineStaff


Work Center Capacities

n You can maintain the available capacity for machines or staff, for example. If one capacity is assigned to several work centers, it is considered a pooled capacity. You should maintain the available capacity of a pooled capacity separately in the work center capacity menu.

n The effectivity of an available capacity can be interrupted by an interval of available capacity with a limited effectivity period. You can maintain intervals of available capacity using shift sequences.

n You must assign formulas to calculate capacity loads on the screen for available capacity.


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Assign factory calendar

Maintain factory calendar

Maintain public holiday calendar

DefinitionPublic holiday calendar ID: 08Public holiday 1. . .Public holiday n

DefinitionFactory calendar ID: 01Public holiday calendar ID: 08Definition of working and free days in the weekSpecial cases

Plant 1000

Maintain public holidays

Define public holiday 1

Define public holiday 2

Define public holiday n

. . .

2.2.

1.1.

3.3.

4.4.Work center - Capacity

Maintaining and Assigning a Factory Calendar

n Work centers only have an available capacity on working days.

n In order to calculate the available capacity, a factory calendar has to be maintained, in which the working days are defined.

n The factory calendar is maintained in Customizing and can be assigned to a plant or an individual capacity, if it differs from the plant.


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Day 5Day 1 Day 2

Shift 1Shift 1

Shift definitionShift definition

Shift 2Shift 2

Shift 3Shift 3

Shift 1Shift 1

Shift 2Shift 2

Shift 3Shift 3

Shift 1Shift 1

Shift 2Shift 2

Work startWork start

Work finishWork finish

Break timesBreak times

. . .

. . . Shift sequenceShift sequence

Work centers / Capacity categoryWork centers / Capacity category

Available Capacity Maintenance using Central ShiftSequences

n You define the work start, work finish and break times for all work centers in a shift definition.

n In shift sequences, you maintain the sequence of individual shift definitions for all shift sequences.


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Move time matrix

min./max.Wait time

Oper. timeMove time

From plantLoc. group

Dest. plantLoc. groupESES

Scheduling dataScheduling basis

formulas

Location groupLocation group

Set-uptime

Processingtime

LSLS

Wait time

Work Center - Scheduling Data

n Move times can be maintained separately in operations.

� You can maintain a minimum move time and a normal move time in the interoperation time section of the operation detail screen. If reduction measures are necessary the system uses the minimum move time for scheduling (also see reduction measures).

� The system uses the move time matrix to determine move times only if you have not entered move times in the operation detail screen .

n As a rule the transport time should be determined using location groups .

� Work centers that are close together are grouped in a location group. You maintain location groups in Customizing.In the work center scheduling data screen, you assign the work center to a location group.

n You can maintain the planned move times within a location group or between two location groups and several plants in the move time matrix.

n You can maintain the wait time in the work center and in the routing operation. The system only schedules using the wait time from the work center if you have not entered a wait time in the operation. If reduction measures are necessary, the value is reduced from the normal queue time to the minimum queue time. The queue time is the difference between the earliest (ES) and the latest start date (LS) for an operation.


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Lead time schedulingLead time scheduling


l Formula keysl Formula constants

OperationOperation

FormulasFormulas

l Standard valuesl Set-up timel Processing timel Tear-down time

l Number of splits

Execution Time

n The standard values defined for the routing and the formulas defined in the work center are used in lead time scheduling to calculate the execution time for the individual segments (setup, processing, tear-down).

n If splits take place, you must also take into account the formula parameters in the formula for the number of splits.


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formulasformulas

Execution timeExecution time

l Setupl Processingl Tear-downl Work (PS)

Capacity requirementsCapacity requirements(per capacity category)(per capacity category)

Costing

PRT

(Y/N)(Y/N)(Y/N)

l Setupl Processingl Tear-downl Work (PS)

l Setupl Machinel Human Resourcesl Work (PS)

ll Command lines (ABAP)Command lines (ABAP)ll GenerateGeneratel Schedulingl Capacity rqmntsl Costingl PRT

l Required quantityl Usage value

Formulas

n Formulas can be assigned to each capacity in the work center to calculate the capacity requirement. At the same time, formulas can also be permitted for different functions (capacity requirement, scheduling, costing).

n Generation controls the immediate code generation for the formula. If no code is generated in formula maintenance, then it is generated at execution time.

n A maximum of 3 lines per formula. Possible arithmetic operations +, -, *, /, SIN, COS, DIV, MOD, SQRT, EXP, LOG.

n Conversion of units of measure takes place automatically.


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Formula definitionFormula definition

Parameter attributesParameter attributes

(short/long)(T006)(fix)

(Operation)

Formula parametersFormula parameters

l Parameter IDl Parameter origin

FormulasFormulas

l Key wordl Dimensionl Standard valuel Unit of measurementl Field name

l General operation valuel Work center constantl Operation standard valuel User field in operationl Value from PRT assignmentl PRT constantl General formula constant

(CR04)

l Definel Generatel Test

Setting Up Formulas

n Formula parameters are differentiated according to their origin. The following origins for a formula parameter can be defined in Customizing:

� General operation value : The formula parameter is linked to a data field in the general operation data. The value of this field is entered in the formula. Typical fields are lot size, base quantity, number of splits (partial lots) and the number of employees

� Work center constant: The parameter is assigned a constant value in the work center. This value is used in the formula.

� Operation standard value: With the help of the standard value key you can assign up to six formula parameters for standard values to a work center and consequently to an operation in a routing.

� User-defined field in the operation: The value of a user-defined field in the operation is assigned to the formula parameter.

� Value from PRT assignment: This could be either the quantity or the usage of the PRT. This parameter can only be used for formulas that are used for PRT management.

� PRT constant: You assign constant values to the formula parameters in the PRT master record. These formula parameters can only be used in formulas for PRT management.

� General formula constant: A value is assigned to this parameter, which is then used in the application.


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Formula parametersFormula parameters

Formula definitionFormula definition

Set-up int.Set-up int. MachineMachine Set up timeSet up time Base quantityBase quantity SetupSetup

F 1

V 1V 1 V 2V 2 ......

The formula definition F2is missing a valuefor a parameter.

Standard value keyStandard value key Other originOther origin

l General operation valuesfor example, split, lot

l User fields from operationl Work center constantl Values from PRT

F 2F 2

Formulas and Standard Values

n You assign formula definitions for calculating execution time and capacity requirements in the work center.

n The formulas themselves are saved in Customizing as formula definitions. You must first maintain the parameters used in the formula definitions in Customizing. You use standard value keys to specify entry fields for standard values. The standard values entered in these fields are used to calculate execution time and capacity requirements.


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Order dates Operation dates Time terms

BSSS

SFBFADLTGIDDD

ES Earliest start dateLS Latest start dateLF Latest finish date

Lead time orderor operation

Float times order

Execution time operation

Interoperation times

Processing times in sales and distribution

OPR 0010

OPR 0020

OPR 0030

OPR 0040

........ OPR 0099


GRProcessing

Pick/pack Loading Transit

Queue time

Set-up time

Process.time

Teardowntime

Queue time

Movetime

LSLSESES

BSBS SSSS SFSF BFBF ADAD LTLT GIGI DDDDDD

LFLF

Basic start dateScheduled start date(Production start date)Scheduled finish dateBasic finish dateAvailability date (expected)Loading timeGoods issueDesired delivery date

Scheduling: Time Element in an Order

Float before production

n There are two floats for different purposes:

� Float before production

� Date shift, capacity planning

� Float after production

� Dealing with malfunctions

n The order float can be predefined in Customizing and the material master (scheduling margin key).

n The duration of an operation consists of a maximum of five time elements:

� Queue time

� Setup time, processing time, teardown time

� Process-related wait time

n The duration of the move time lies between two operations but is assigned to the preceding operation.

n The material requirement is scheduled from the earliest start date. (Changeable in Customizing)

n The capacity requirement can be displayed on the earliest or latest start date.


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OriginOriginTime elementsTime elements

Move

Wait

Tear-down

Processing

Queue

Setup

Float after prod.

Float before prod.

Work center or work operation

Operation

+ Work center - formula

Work operation - standard values

Work center or work operation

Customizing and material master

Customizing and material master

Order float

Queue times

Executiontime

Queue times

Time Elements and their Origins

n You maintain time elements for lead time scheduling in various places within the PP application.

n It is important to make the correct settings and use the system properly for successful scheduling.

n The interoperation time in the material master is calculated from:

� Order float (float before and after production) +

� Operation float (queue time) +

� Wait time +

� Move time


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Float

Move

Queue

Wait

Processing

l Minimum queue time(work center)

l Optional split

l Optional overlap

l No reduction

l Minimum move time

l Float before and afterproduction

Reduction Measures

n The system can carry out reduction measures in lead time scheduling for orders.

n You can set the time elements that can be reduced as well as the reduction strategy in Customizing (for each order category and routing group).

n You can also specify reduction for the floats before and after production in the order or in Customizing for each plant, order type and routing group.


SAP AG 1999

l You now understand the scheduling relevant datain the routing administration and in the systemsettings.

l After a new creation or a scheduling relevantchange to a routing, it is important to schedule thisrouting and to update the in-house production timein the material master.

Scheduling: Summary


Exercises

Unit: Scheduling

Topics:

• Scheduling routings

• Updating scheduling results

• Creating and testing formulas


• Carry out routing scheduling and update the in-house production time in the material master.

• Create and test formulas

As a member of the project team you are responsible for feasible and exact scheduling of the company’s products

The following prerequisites need to be fulfilled:

• Lead time scheduling of a routing

• Preparation of reduction measures

• The in-house production time is maintained in the material master

• Setting up of formulas

1-1 Schedule the new pump, T-F##, based on the routing you completed in the unit 5.

1-1-1 Schedule the pump T-F## with a forwards scheduling direction from today’s date and for a quantity of 100 pieces. Use the operation segments overview variant to view the schedule data.

1-1-2 Why is there no processing time calculated for operation 10 in the parallel operation when the machine time of 10 minutes per unit is defined as required for each unit?

______________________________________________________

______________________________________________________

1-1-3 Display the Gantt Chart for your schedule.

1-1-4 Display the scheduling log and review the types of messages you have received, if any.

1-1-5 Review the scheduling results. How many interoperation times are scheduled? ____________________________

1-1-6 Mark the material master for T-F## to be updated with your scheduling results.


1-2 Execute the update of the lot-size dependent in-house production lead-times in the material master for T-F##, for production scheduler 0##.

1-2-1 Update the production lead-times based on the marking activity you performed in exercise 1-1-6.

1-2-2 Review the results of your update in the material master for T-F##. Are the values updated lot size dependent or independent?

______________________________________________________

(Optional)

1-3 Create a formula for repeating set-up periodically at a work center. In order to be able to create and test the formula, it is necessary not just to define the formula parameters for the formula, but also to define a standard value key that supplies the formula with values.

1-3-1 First define a formula parameter for the additional set-up time and a formula parameter for the period, expressed as a quantity, after which the set-up is to be repeated. The parameter values should have their origin in a standard value in the operation.

Data for the group parameters:

Periodic set-up Set-up int.

Parameter SAP1## SAP2##

Short keyword PS-group ## Set-up int.

Keyword Period. set-up SI-group ##

Dimension Time

Standard value 1

Std. value unit Minutes Piece

1-3-2 Now define a formula for periodic set-up at your work center. Call the formula SAP1## with description "PS group ##". This formula should only be valid for scheduling and should be generated immediately when you save. Use the parameters from exercise 1-3-1.

The formula is: Machine * operation quantity / Base quantity + period. set-up * (( Operation quantity DIV set-up int. ) – 1)

1-3-3 Define a standard value key, so that the parameters in the formula can be supplied with values. The standard value key should allow entries for set-up time, machine time and additional set-up after 50 pieces. The key name should be GR## and the description "PS group ##".


1-4 Test the formulas on the scheduling screen of a new work center.

1-4-1 Create a new work center FT-##. Use the work center 206-## you created in unit 4 to copy from. Copy the Basic data, Default values, Capacities Scheduling and Costing screens. The description of the work center should be "Formula test ##". Save the work center.

1-4-2 Replace the formula for processing execution time by the formula key SAP1## that you created in exercise 1-3-2. Pay attention to the warning message after you have confirmed the entry.

1-4-3 In the exercise 1-4-2 a warning appeared, which you now want to process. Make the relevant changes in your work center.

1-4-4 Now test your formula on the scheduling screen. Enter the following values:

Operation quantity 101 pieces

Set-up time 10 minutes

Machine time 1 minute

PR-group ## 5 minutes

SI-group ## 50 pieces


Solutions

Unit: Scheduling

Topics:

• Scheduling routings

• Updating scheduling results

• Creating and testing formulas

1-1 Logistics → Production →Master data → Routings → Routings → Standard Routings → Change

1-1-1 From the operation overview, use the menu path

Extras → Scheduling→ Schedule.

1-1-2 The machine time has been defined, however, the labor time is needed to complete the work center formula. (check the processing formula for work center T-V)

1-1-3 Choose Gantt Chart or Extras → Scheduling→ Gantt Chart

1-1-4 Choose Scheduling log or Extras →Scheduling → Display log

1-1-5 Choose Scheduling results or Extras → Scheduling→ Sched. results.

1-1-6 Choose Update mat. master to mark the schedule for update.

1-2 Updating the material master

Logistics →Production → Master data → Routings → Extras → Material master → Update mat. master

1-2-1 Make sure you select only your T-F## for update. Once the update is complete, you will see a message saying that the material has changed.

1-2-2 Displaying the material master

Logistics → Production → Master data →Material master→ Material → Display → Display current

Choose the Work Scheduling screen to view the production lead-times.


1-3-1 Creating a formula parameter

Tools → Accelerated SAP → Customizing → Edit project Then SAP-Reference-IMG → Production → Basic data → Work center → General data → Standard values→ Define parameters

1-3-2 Creating a formula

Tools → Accelerated SAP → Customizing → Edit project Then SAP-Reference-IMG → Production → Basic data → Work center → Capacity planning → Work center formulas→ Define formulas for work centers

1-3-3 Creating standard value keys

Tools → Accelerated SAP → Customizing → Edit project Then SAP-Reference-IMG → Production → Basic data → Work center → General data → Standard values→ Define standard value key

1-4 Testing formulas

1-4-1 Creating a work center

Logistics → Production → Master data → Work centers → Work centers→ Create.

Enter your work center 206-## in the Copy from field on the initial screen. On the Copy from dialog box select the Basic data, Default values, Capacities, Scheduling and Costing screens.

Description: Formula test ##

Display all screens

Save

1-4-2 Replacing the formula key

Work center → Change

Go to the Scheduling tab page and overwrite the key SAP002 with SAP1xx.

1-4-3 Replacing the standard value key

Go to the Basic data tab page and replace the standard value key SAPl with GR##.

Delete the Efficiency Rate from the SET UP key.

1-4-4 Test

Return to the Scheduling tab page, choose Test formula, enter the values, and choose Calculate.

The calculated overall execution time is 116 minutes. Set-up was repeated twice.


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l Introduction to the Engineering Workbench (EWB)

l Changing, copying and so on, of Workbench objects

l Simultaneous work in the EWB

l EWB system settings

Contents:

Engineering Workbench


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l Navigate in the Engineering Workbench

l Maintain working areas

l Use the EWB browser functions


Engineering Workbench: Course Objectives


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l An optimal maintenance environment is to be usedfor the permanent changes incurred.

l Changes are to be carried out simultaneously.

l New master data and its links are to be createdhierarchically.

Engineering Workbench: Business Scenario


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l To support complex planning processes

l To carry out parallel processing

l For precise selection of objects from routings andbills of material (BOMs)

l For the integrated processing of operations anditems

l For the precise setting of locks

l To show the development of the change status

Why the Engineering Workbench?


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Activities

Routings BOMs

Objects to be processed!

BOMsRoutings

Database

Formatting of Specific Information

n Activities can arise from new development, design changes and changes in procedure.

n Design changes Changes that, for example, are required due to new products, rules, warranty dates and so on.

n Technical changes: BOMs, routing changes, for example, new procedures (work center), call for changes to the assembly in the BOMs / to the sequence in the routings.


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Worklist

Worklist - Purpose

n The Engineering Workbench is a maintenance environment for product structures and PP objects, its capabilities far exceed those of the conventional maintenance of BOMs and routings. You do not have to process routings and BOMs separately.

n The most important objects of the Engineering Workbench are BOM items and operations. Views are applied to these objects, which then further enable the conventional BOM or routing structures to be used. The full scope of the processing functions, for example:

� Create

� Change or

� Delete is supported in all these views.

n The worklist contains the selected objects, so that they can be displayed, changed or newly created in the Engineering Workbench. These objects are copied by the system from the database into the worklist. Only when the worklist has been saved, following the processing of objects, are new objects created in the database or existing ones changed or deleted.


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1 2

Worklist 1 Worklist 2

Simultaneous Processing of Objects

n Any number of operations from any number of routings can be processed at the same time by different people . The same applies to different BOM items. If you want to process an operation that is already being processed by someone else, the Engineering Workbench information will show you who to contact, so that you can consult with the other processor. The processor can then release the operation (for example the BOM item) to you, without interrupting your work on other objects.


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BOM headerBOM header

Sub-itemSub-item

SequenceSequence

Task list headerTask list header

Sub-operationSub-operation

PRTPRT

Trigger pointTrigger point

Inspection characteristicInspection characteristic

OperationOperation

MaterialMaterial

Componentassignment

Materialtask list

assignment

MaterialBOMassignment

ItemItem

Structure of the Engineering Workbench

n In order to display or process an individual object using the EWB, you have to select the corresponding object.

n Examples of objects are:

� The task list header of a routing

� The operation and sub-operation

� The production resource/tool, trigger point and inspection characteristic

� The BOM header

� The item and sub-item in the BOM

n An object can also take the form of an assignment between individual objects. Examples of assignment objects are a material-routing assignment, material-BOM assignment and a component assignment.


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Toolbar

Cockpit Process using Effectivitywimdow

Context

21.09.1999 AE-12345 15.09.1999 31.12.2000

F-100 1000

M 00000629 1

Pump

Pump change number

OverviewscreenFor exampleItems

General items Status MRPVariable-size part

Purchasing Class Management

Spe ItemID Item O PT Components Component descriptionA Quantity UN

Screen Layout

n The screen layout is divided into the elements: Toolbar, Cockpit and Overview screen.

n The Toolbar provides the user with currently available functions at the touch of a button.

n The Cockpit is always available in the Engineering Workbench and controls the Engineering Workbench. It consists of three areas:

� Process using , for the entry of the key dates or of the change number, in order to process the objects in the worklist. The entry of a key date or a change number is necessary when an object has to be created, changed or deleted.

� Effectivity window, in order to display a particular time segment of the worklist.

� Context, to display the hierarchical relationship of objects in the overview screen. In this slide there is an input line for each material, BOM and item.

n The overview screen list objects that are contained in the worklist and that match the entries in the effectivity window and in the context. It provides information about the object and change status of a particular object type.


SAP AG 1999

WorkingenvironmentFocus


Sub-itemSub-item

SequenceSequence



PRTPRT



OperationOperation

MaterialMaterial

Componentassignment

Materialtask list

assignment


ItemItem

Working Area 1

n You do not have to process routings and BOMs separately. You simply choose the engineering object type, for example, material, operation, and so on, with which you want to work. You group your choices together in a working area.

n The working area consists of the focus and the working environment. The focus is the object type that you use for selection. The other object types that you want to display and process form the working environment. Focus objects can be: task list header, operation, BOM or item.

n In the working area you specify which object types you are interested in.

n A working area can be specially adapted for your production or engineering/design, for example with reference to processing.

n As focus of a working area only the object types task list header, operation , BOM or item can be supported. In addition, the focus controls the input screen for the selection. In this slide, the example is of an operation.

n All remaining object types in the working environment that have not been restricted by the working area can be contained in the Workbench.


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Working Area 2

WorkingenvironmentFocus


Sub-itemSub-item

SequenceSequence



PRTPRT



OperationOperation

MaterialMaterial

Componentassignment

Materialtask list

assignment


ItemItem

n The working area consists of the focus and the working environment. The focus is the object type that you use for selection. The other object types that you want to display and process form the working environment.

n On this slide the operation has been chosen as the focus of the working area.

n All remaining object types in the working environment that have not been restricted by the working area can be contained in the Workbench. On this slide, the object types PRT, trigger point, inspection characteristic and sub-item have been excluded.


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Operation BOM header Item Sub-item Task list header

Processing using Selection area

EWB: Select working area

Setting working area

• Current working area

• Standard working area

P_ALLES

P_ALLES

Select working area

n The working areas are created in Customizing the Engineering Workbench.

n Using the Display working area button, you can specify a standard working area or select another working area.

n In the dialog box Select working area you also have the option of branching to the detail screen in the working area. In this detail screen you can read the information about the predefined focus and about the object types contained in the working area.


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Selection Criteria

Operation BOM header Item Sub-item Task list header

Processing with Selection area

Field from the structure: item

l Created byl Changed byl Bulk material

n You can use the selection range to restrict the time period for the data. Only data that lies entirely or partially in the validity period is copied into the worklist.

n The system automatically offers the tab page in which the object of the focus has been placed. When entering the selection criteria you can switch the tab page.

n By using the arrow key on the tab page you can enter into fields additional selection criteria that is not contained as selection criteria in the tab pages on the screen. In addition, you can also use this procedure when you want to select according to several individual values, value intervals or generically.


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Objects in the Worklist

Focus object

Standard sequenceStandard sequence


Sub-operation 10/10Sub-operation 10/10

Operation 10 Operation 10

MaterialMaterial

BOM header BBOM header B

BOM header ABOM header A

Item B1Item B1

Item A1Item A1

.....

.....

Environment object

n A focus object is an object of the focus object type that meets the selection criteria that you have entered. An environment object is an object whose object type is contained in the working environment and that is assigned to a focus object. Environment objects are automatically selected by the system and display the 'environment' of the focus object that you are interested in.

n Using the selection criteria that you enter, you immediately determine which focus objects are contained in your worklist. The focus objects form the 'core' of your worklist.


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FocusBOM headerBOM header

Sub-itemSub-item

SequenceSequence


PRTPRT



OperationOperation

MaterialMaterial

Componentassignment

Materialtask list

assignment


ItemItem

4

31

2

Example: Focus Task List Header

Working environment


n The focus lies on the object type task list header. In addition to the focus task list header, the object types sequence, operation, PRT, trigger point, inspection characteristic, BOM header, item and sub-item should all be contained in the working environment.

n A work list has been entered as selection criteria.

n For 1: All task list headers are copied into the worklist provided they have an operation that has been executed in the work center. Additionally, the objects that are connected to the operation and whose object type is included in the working environment are also copied into the worklist.

n For 2: All BOM headers that are assigned to these task list headers are copied in to the worklist.

n For 3: All objects that are on a lower level to these BOM headers are copied into the worklist.

n For 4: All component assignments that exist between the operations of the task list header and the item of the assigned BOM headers are copied into the worklist.


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Working environmentFocus


Sub-itemSub-item

SequenceSequence



PRTPRT



OperationOperation

MaterialMaterial

Componentassignment

Materialtask list

assignment


ItemItem

2

1

1

3

3

4

Example: Focus Operation

n The focus lies on the object type operation. In addition to the focus operation, the object types task list header, sequence, PRT, trigger point, inspection characteristic, BOM header, item and sub-item should all be contained in the working environment.

n A work list has been entered as selection criteria.

n For 1: All objects that are at a higher or lower level than the focus objects covered by these work center operations are copied into the worklist.

n For 2: All items that are assigned to these operations, including the component assignments, are copied into the worklist.

n For 3: All objects that are on a higher or lower level than these items are copied into the worklist.

n For 4: The assignments between last list headers and BOM headers, determined in steps 1 and 3, are copied into the worklist.


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Focus

Selection

Results

All task list headersAll sequences

Only operations for the location

Operation

Workcenter


All operations for the routings

Workcenter

Task listheader

Routing: Different Focus

n These examples illustrate the expected results of the different focus.

n Prerequisite for the respective results is that the working area always contains the same object types.

n The working area (with focus) and the selection criteria can be viewed in the menu entry Extras:

� Working area details

� Selection criteria details


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Working area


All operations for the routings

Selection

ResultsAll task list headers

All sequencesAll operations for the routings

All PRTsAll BOM and items for the

routings

Operationonly

Workcenter

Workcenter

Complete

Routing: Different Working Area

n These examples illustrate the expected results of a different working area.

n Prerequisite for the respective results is that both examples use the same focus.





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Effectivity window=

Selection period

Restricted

effectivity window

Effectivity window=

Key date

Effectivity Task List

n With the help of the effectivity window, the display of objects is filtered into the overview screen.

n In this slide the example is of a working area with four operations. The operations have been partially changed.

n If you choose the selection period in the effectivity window, all operations that are effective in the selection period are displayed.

n If you restrict the effectivity window, the operations that lie completely outside of the effectivity window are not displayed.

n If you choose the key date in the effectivity window, only those operations that are effective on the key date are displayed.


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Task list header ATask list header A

Summ. op. 11Summ. op. 11





Becomes referenceoperation set

operations can notbe transferred

Work Center Operation Set

Reference operation setReference

operation set



n The work center operation set is a summarized reference operation set and can no longer be exploded in a routing. It is a subordinated work center necessary for the standard value summarization. The standard value summarization has to be triggered manually. Detailed operation descriptions along with executed work centers are no longer contained in the work center operation set You can manually overwrite the summarized standard values.

n No objects can be assigned to a work center operation set. These are transferred from a reference operation set.


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Function

SAP object

MaterialTask list header

Sequence

Operation

BOM

Item

Overviews Assignments Change or delete

Copyhierarchically

Mat. BOMMat. routing

Mat. routing YesBrowser noEWB yes

Change No

Components Yes Yes

Yes

Components Yes Copy item

Browser noEWB yes

Functional Overview of the EWB

n Prerequisites: Copy range has to include the object to be copied. The copy range is predefined with the settings from the working area and also those from the restrictions . No objects an be expanded unless they are contained in the working area. Should the situation arise, check under Extras -> Options -> Copy range.

n Navigation

� EWB menu options routings; BOMs

� In the Browser

Double click on an object, the context block is filled in the EWB window and the tab page belonging to it is displayed.

The right mouse button provides the functions from the graphics displayed above in a context menu.


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l Use the Engineering Workbench to navigate,execute changes and copy objects

l Maintain working areas

l Work with the Engineering Workbench Browser


Engineering Workbench Summary


Exercises

Unit: Engineering Workbench

Topic: Working with the Engineering Workbench


• Work with the Engineering Workbench

• Maintain working areas

• Use the browser functions

You and other colleagues are responsible for the creation of engineering data in your company. You use the Engineering Workbench for the joint processing of BOMs and routings.

1-1 Working with the Engineering Workbench

1-1-1 You optimize your business process for pump T-Fxx by using a PRT. Use the Engineering Workbench (EWB) with working area P_ALLES to maintain data. Use the EWB to add the PRT with material master PP-FHMM to operation 20 on today’s date, and change the labor time to 12 minutes.

1-1-2 You also want to assign your routing to another pump and need the material number from a colleague for that.

Normally you know the name of the colleague. For this exercise you get the name of the colleague as the group name from the instructor.

Under additional selection criteria, you select changed by and make a note of the material number.

1-1-3 Execute a material-task list assignment for your task list group with the material number of your colleague for your pump.

The selection criteria for the user is saved in the database. This is not deleted by a new log on.

1-1-4 Replace the work center in operation 30 using work center 1906 in the routing, with the smaller task list group number and the group counter 1.


In order to see the locking propertie s, you should carry this exercise out in cooperation with the allocated group.

Alternatively, you can also learn the locking properties with a change to the operation 30 in a second session.

1-1-5 Using the change number T-AE22, carry out a mass change to your routing. Select all operations and increase the standard values for the set-up by 10%.

You can only carry out mass changes to operation data on the screen Operation overview.

Display the routing on the date of the change master, without leaving the EWB.

1-2 Create working area

1-2-1 Create a new working area 206-xx with description “Group ##’, for your group with the focus on the task list header. The task list header, operation and material routing assignment objects should be contained in the working area.

1-2-2 Using the working area that you created in exercise 1-2-1, assign material components from material BOM T-F## to operations.

1-2-3 If you incur problems in exercise 1-2-2 look in the working area and describe which objects are missing.

______________________________________________________

1-3 Copy hierarchically

1-3-1 You want to create the engineering data for a new product with the material number T-FP##. To maintain the BOMs and routings, you take a similar product (T-F##) and use the function Copy hierarchically. Before you copy, make sure that all the objects that you want to copy are also contained in the working area.


1-4 Working with the Engineering Workbench browser.

1-4-1 Choose working area P_ALLES and activate the browser. Use the browser to navigate around the standard sequence of the routing (by double clicking), and select the operation overview from the menu. In a similar way, try to get to the item overview of the BOM.

1-4-2 Use the browser to assign to another operation, a component that is already assigned.

1-4-3 Use the browser to find the PRT PP-FHMM, and determine which operation this PRT has been assigned to.


Solutions

Unit: Engineering Workbench

Topic: Working with the Engineering Workbench

1-1 Call up the Engineering Workbench with the working area P_ALLES for material T-F## and click on Execute.

Logistics → Production → Master Data → Engineering Workbench

Process using: Today’s date

Current working area: P_ALLES

Material: T-F##

1-1-1 Select the task list header and choose Task lists → Operations.

Select operation 20 and choose

Task lists → Production resources/tools.

Choose the tab page Material and enter the PRT.

Go back to the operation overview and change to the Processing times tab page in order to change the staff default values.

1-1-2 From the task list header selection criteria screen delete the material number and click on Edit → Additional selection criteria. Open up the Explorer and select Changed by. Click on Adopt selected items and enter the colleague. Go back to the task list header selection criteria screen and click Execute. Select the task list group and choose

Task lists → Material routing assignments.

1-1-3 On the task list header overview, select the task list group with the group counter and choose

Task lists → Material routing assignments

Click on New entries. In the dialog box enter a key date or a change number.

If you had already changed this routing with a change number you still have to enter another change number here.

1-1-4 In the Task list header overview, choose a smaller task list group number and go back into the operation overview. Now select operation 30 and click Change. You can now overwrite the work center.


By working with the allocated colleagues you will determine that for changing the same object, the first user has already locked the object (operation) for other processors.

1-1-5 From the operation overview change to the Processing times tab page. Select all operations and the column for the set-up time on the operations overview. Choose Extras → Mass changes.

In the dialog box, enter the change number and in the next dialog box click Enter formula. The formula is 1.1 * X.

In order to display the routing on the date of the change master you have to switch to the effectivity window.

1-2 Create working environment

1-2-1 Customizing → Production → Basic Data → Engineering Workbench → Process Working Environments: Execute.

1-3 Copy hierarchically

1-3-1 Call up your material using the EWB and select the task list group from the task list header overview.

Click Copy. After entering a key date, enter the material for the regenerative planning in the next dialog box. Mark Copy hierarchically and click Options. All the objects which you want to copy hierarchically have to be selected on this screen.

These options are saved to the user.

The material master record has to exist for the new material.

1-4 Working with the Engineering Workbench browser.

1-4-1 When entering the Engineering Workbench (EWB: Selection criteria for task list headers) choose Select working area (F6). After entering the browser click Activate browser (Shift + F9).


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Summary


SAP AG 1999


l Create, change and delete material master records

l Configure the field selection and the user-specificmaterial master record

l Create, change and delete material BOMs

l Configure BOMs

l Analyze BOMs

l Process variant and multiple BOMs

Basic Data: Section Summary (1)


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Basic Data: Section Summary (2)


l Describe PP's primary basic data elements

l Maintain work centers and routings

l Process material components and assign them tooperations

l Schedule routings and update the scheduling datain the material master

l Work with the Engineering Workbench


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Recommended Follow-up Activities

l Go through the exercises using IDES data or your own data

l Read on-line documentation

l Read IMG documentation

l Read release notes


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Appendix

l Technical Details - Material Master

l Technical Details - Bill of material

l Application menu paths

l Distributed data: ALE

Contents:


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Development class(es)Function group(s)Module poolLogical database(s)

MG, MGA ..M....SAPLMGMM, SAPLMGD1None

Number range object(s)NR element

NR group tableNR group(s)NR transaction(s)Authorization classAuthorization object(s)

MATERIALNR01 internal02 externalNoneGroup 1MMNR Material Master M_AENR_BGRMaterial master authorization group

Lock object(s)Change document object

EMMAR* (several) EMVKE*None

Matchcode object(s)Message class(es)Archiving class(es)Archiving object

MAT1, MAT2, MCH1MM, M3, WE, MG

Profile(s) MRP-profile, forecast-profile

Technical Details for the Material Master


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MARA

MARC

MAKT MARM MVKE MLAN

MLGN

MARD

MLGT

MEAN MBEW

MAPRMVER

Material Master - Table Structure

n The individual tables contain the following data: MARA General data

MAKT Descriptions/short texts MARM Conversion factors MVKE Sales data per sales organization MLAN Sales data per country MEAN EAN (European Article Number) data MBEW Valuation data MARC Material data per plant MLGN Material data per WM warehouse

MLGT Material data per WM storage type MARD Material data per storage location

MVER Consumption data MAPR Forecast data (pointer)


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Technical Details for BOM Management

Development class(es)Function group(s)Logical database(s)

CSCSXXCDC, CEC, CKC, CMC, CSC, CTC

Number range object(s)NR transaction(s)Authorization classAuthorization object(s)

STUED. STUEE, STUEM, STUEK, STUES, STUETCV91 IB90 CS90 CS92 CS91 IB91Production planningC_STUE_BERC_STUE_WRKC_STUE_NOH

Lock object(s) ECEXSTLE, ECEQSTE, ECDOSTE, ECMASTE,ECTPSTE, ECSTSTE, ECKDSTE

Collective search helpSearch help

Archiving class(es)Archiving object

Profile

STZ1STZ1D, STZ1E, STZ1M, STZ1T

CS_BOMBOM

User-specific default values

n BOM numbers are only stored internally. You do not need to define any settings.


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Table Structure for BOM Management

STAS

STPO

STPU

STKO STZU

TPSTDOST EQST MAST KDST STST

n The individual tables contain the following data:

MAST Assignment of BOM to material

EQST Assignment of BOM to equipment

DOST Assignment of BOM to document

KDST Assignment of BOM to functional location

KDST Assignment of BOM to sales order

STST Standard BOM assignment

STKO BOM header data

STZU Permanent BOM data

STAS BOM item selection

STPO BOM item data

STPU BOM sub-item data


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Material Master User Exits: Number Assignment (I)

l Internal Number Assignment

Number assigned when you create material, not when you save it.

l Customer Enhancement MGA00001

(Exit: EXIT_SAPLMGMU_001, module MATERIAL_UPDATE_ALL)

Completes checks for customer-specific fields.

Extends checks for existing fields.

Can change material data (restricted).

Example: enter basic material, material group, and consecutive number asmaterial description.


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Material Master User Exits: Number Assignment (II)


(Exit: EXIT_SAPLMG02_001 for internal number assignment, moduleMATERIAL_NUMBER_GET)

Influences internal material number assignment:

n Internal number changed by customer program. Example: program takesinternal material number from number range, attaches it to the materialtype, and saves the new number.

(Exit: EXIT_SAPLMG02_002 for external number assignment, moduleMATERIAL_NUMBER_GET)

Influences external material number assignment:

n External number changed by customer program. Example: program addscheck digit to external material number.


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Material Master User Exits: Number Assignment (III)


(Exit: EXIT_SAPLOMCV_001 and EXIT_SAPLOMCV_002 ,EXIT_SAPLOMCV_901 and EXIT_SAPLOMCV _902 , module:MATERIAL_UPDATE_ALL) MATERIAL_UPDATE_ALL)

Influences material number display format:

n Example: Converts the material number from #### to MAT-####

Caution: Problem using the search help, for example, using the searchterm M*

Result 1: All materials starting with MAT-Result 2: All materials starting with MAT- M


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External Processing

Control key indicatesif external processing

is allowed andpurchasing data is

required.

Operationnumber

Workcenter

Controlkey

Description

10203030405060

1310140014101410150016001800

PP01PP01PP02PP02PP01PP03PP99

Sheet metalDrill and punchHeat treatHeat treatFinal assemblyInspectionStorage location

External Processing Data: Operation Detail Screen

Purchasing info recordSort stringPlanned delivery timeVendorNet priceCost element

Purchasing organizationMaterial groupPurchasing group

Price unitCurrency

n External processing allows production operations performed outside of your facilities to be defined in the same manner as internal operations. The vendor is treated as an extension of your production facility. In order to use external processing a control key must be defined that indicates that external processing is allowed.

n When an operation is created with an external processing control key, you will be required to enter purchasing data on the operation detail screen. As a minimum, you must define the following:

Purchasing organization

Sort string

Material group

Planned delivery time

Cost element


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l Definition

n Automatic posting of a goods issue for components some timeafter their actual physical issue for use in an order. The goodsissue posting of backflushed components is carried outautomatically during confirmation.

l Use

n Backflushing is used to reduce the amount of work in warehousemanagement, especially for low value parts.

l Prerequisite

n Accurate bills of material and routings

l Recommendations

n Assignment of components to operations

n Confirmation required for operation using milestone

Backflushing

n To use backflushing effectively, the material components from the BOM that are required in the operation should be assigned to the operations in the routing.

n By assigning components to an operation, you specify that this material is first required at this point in time. Since these components have a low value, they do not need to be staged explicitly. When the operation is confirmed, the values and the quantities of the components are posted.


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Backflushing: Settings

l Backflush indicatorl In the material masterl In the work center

l Assignment of material component tooperation

( Backflush indicator for materialcomponent in routing

( Assignment of a control key withmilestone confirmation isrecommended

156 Connector


Contact Nylon Housing

RoutingRouting

Product:Group:Counter:

156 Connector0000009851

Oper.No.102030

Workcenter131014001410

ControlkeyPP98PP01PP99

OperationtextAssembleInspectPackage

n Backflush determination is a multi-step process:

� First the system looks at the component assignment data to determine if the backflush flag is set. If set the component will be backflushed.

n If not set, the system checks the material master. If the material master backflush indicator is:

� Not set, no backflushing will occur.

� Set to always backflush, the component will be backflushed.

� Set to let the work center decide, the work center of the operation to which the material is assigned is determined and the work center's backflush indicator checked.

n Operations, which are not milestones, should have control keys with confirmation rules set to optional or prohibited reporting.


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l Single manufacturing process produces multiple products(co-products) simultaneously.

l Examples:

n Several different sized connector housings are manufactured byone mold base in a mold machine.

n During stamping, plugs are produced. The high quality waste isinventoried, valued and sold to scrap dealers.

l Co-products are maintained in:

n In the material master

n In the BOM

Co-Products

n A co-product is a product manufactured in conjunction with another product during a manufacturing process.

n In the material master, you define whether a material can be a co-product and establish the rules for cost apportionment for each product.

n Identification as a co-product will require the quantity to be entered as negative value indicating a planned production receipt rather than a planned material issue.


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CAPP Standard Value Calculation

Basics- Technical data- Processes- Methods- Tables- Formulas- Characteristics

Functions- Standard value calculation- Simulation- Where-used lists

Computer Aided Process Planning (CAPP)Computer Aided Process Planning (CAPP)Standard Value CalculationStandard Value Calculation

Results- Standard values- Sub-calculation description

- Calculation details

n CAPP supports the calculation of operation standard values based on technical data, process information, and so on.

n You calculate standard values using methods that are assigned to one or more processes.


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Standard Value Calculation

Tablesformulas

CTNO*TC** * = Cut no.

** = Time/cut

MethodsValue type -> OPERValue determination

ProcedureOperation text

Preferred methods

Work CenterTechnical data

TurningTurningDrillingDrilling

DraggingDragging

Set-up timeSet-up timeAncillary timeAncillary time

Processing timeProcessing time

n Three processes are assigned to a work center in the technical data.

n A process describes a production technique. All methods that can be used to calculate the standard values of a production technique are combined in a procedure.

n The method along with the value type determine which standard value is to be calculated, for example, setup, machine, labor.

n When you determine the method, you access formulas that, in turn, access other formulas and/or tables.

n Characteristics are used in formulas to calculate standard values. A characteristic describes any detail or feature of an object, such as the length of a screw.


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Data Transfer Programs

Direct input process

Function module

(background processing

only)

SAPDatabase

Batch inputprocess

Screen(in dialogor in the

background)

Formatting of theFormatting of themaster data master data

in SAP formatin SAP format

Master data Master data in the in the

old systemold system

n SAP provides the file layout for each master file.

n The user must create an SAP master file using the file layout provided and then write a conversion program to extract the legacy system data and transfer it into the SAP master file in the SAP format.

n Once in an SAP format the user can update the SAP database using the direct input or batch input process.

n Regardless of the input process used, the SAP System performs its normal data validation routines.

n The data transfer process is covered in course BC420.


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EngineeringEngineeringEngineering

ALE ALE

ALElProduction BOMlMaterial Master lPRTslDocuments

lEngineeringBOMlMaterial Master lDocuments

Product StructureProduct StructureProduct Structure

BOM dataDocumentsMaterial where-usedlist

Product

ProductionR/3

System

R/3System

Product Data / Distributed Systems

n Objectives:

� To use an SAP System with special Customizing as a PDM system

� To use ALE for any necessary data transferal between SAP PDM and SAP ERP

n Advantages:

� Independent release upgrades

� Distributed load on the system

� Heterogeneous SAP System infrastructure possible


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Process new displayProcess new display blocks blocks

Create list profileCreate list profile1.1. LO205SMXM

SAPCSSMXMP01Block 1

Block n

SAPCSSMXMP01Block 1

Block n

LO205SMXMLO205 BL1

4.4. Block n

Copy

Reference

Check new profileCheck new profile5.5.

Create standard profileCreate standard profile (Structure explosion => (Structure explosion => Display blocks)Display blocks)

2.2.

Create display blocks Create display blocks for new profile for new profile

3.3.

Display Profile for Lists

4.4.

n In the standard SAP System, a list profile is defined for every reporting function. This is copied as the default value for the display profiles. You can create a new profile by using a standard profile.

n The name of your own list profile must not begin with 'SAP'.

n You cannot change standard profiles.

n The number of display blocks in your profile must be the same as the number of blocks in the corresponding standard profile.

n The number of selection fields for each display block is determined by the maximum display block.

n Naming conventions for standard profiles: Example: Explosion of the single-level BOM SAPCSLBLMP01

SAP = Standard, CS = BOM LBL = Level by Level => BOM level-by-level MLV = Multi-level => Multi-level structure WSD = Where used => Usage SMX = Summarized explosion => Summarized BOM M = Material D = Document P01 = First profile P02 = Corresponds to formatting in R/2


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Standard Profiles

l BOM level by level: SAPCSLBLMP01

l Multi-level structure: SAPCSMLVMP01

l Summarized BOM: SAPCSSMXMP01

l Material use: SAPCSWSDMP01


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Focus

Selection

Results

all task list headersall sequences

only operations for the location

Operation

Workcenter


all operations for the routings

Workcenter

Task listheader

Different Focus / Routing

n These examples illustrate the expected results of a different focus.

n Prerequisite for the respective results is that the working area always contains the same object.





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Working area


all operations for the routings

Selection

Resultsall task list headers

all sequencesall operations for the routings

all PRT´sall BOMs and items for the

routings

Operationonly

Workcenter

Workcenter

Complete

Different Working Area / Routing

n These examples illustrate the expected results of a different working area.

n Prerequisite for the respective results is that the focus is always based on the same object.





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Screen Layout

Cockpit

Toolbar

OverviewScreenfor exampleoperations

Gen. operations Processing time Interoper. times Control data Extra oper. data Ext. processing

Seq Oper. ID. Ref.Oper. Ref.Rout. Oper Work Ctr.Lo ContWk Copy

Process using Effectivity window

Context

023078099950000317 1N

1000 Pump

n The screen layout is divided into the elements: Toolbar, Cockpit and Overview Screen.

n The Toolbar provides the user with currently available functions at the touch of a button.

n The Cockpit is always available in the Engineering Workbench and controls the Engineering Workbench. It consists of three areas:

� Process using , for the entry of the key dates or of the change number, in order to process the objects in the worklist. The entry of a key date or a change number is necessary when an object has to be created, changed or deleted.

� Effectivity window, in order to display a particular time segment of the worklist.

� Context, to display the hierarchical relationship of objects in the overview screen. In this slide there is an input line for each material, BOM and item.

n The Overview Screen lists objects that are contained in the worklist and that match the entries in the validity window and in the context. It provides information about the object and change status of a particular object type.


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Work Center Operation Set


Task list header ATask list header A







Reference operationset

becomes

Work CenterOperation Set

operations can notbe transferred

summarized oper.11summarized oper.11

n The work center operation set is a summarized reference operation set and can no longer be exploded in a routing. It is a subordinated work center that is necessary for the standard value summarization - the standard value summarization has to be triggered manually. Detailed operation descriptions along with executed work centers are no longer contained in the work center operation set. You can manually overwrite the summarized standard values.

n No objects can be assigned to a work center operation set - these are transferred from a reference operation set.