SAP R/3 Enterprise 2003/Q2 Material number: 5005 9586
Copyright
Copyright 2003 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. All rights reserved.
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Course Prerequisites
SAP01 - SAP R/3 Overview PLM100 - Life-Cycle Data Management Overview or SAPSCM - Solution Overview for mySAP SCM
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Target Group
Participants: Project team members and business requirements analysts who are responsible for material master records and bills of material.
Duration: 2 days
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Course Overview
Contents of Unit z Course goals z Course objectives z Course overview diagram z Main business scenario
Contents: Organizational levels for the material master record Organizational structures Material type and industry sectors Views Number assignment Units of measure Using documents Material status Deleting and archiving Classification
At the conclusion of this unit, you will be able to Distinguish how organizational levels, material type, industry sector, and material status affect the material master record. Maintain options for number assignment and units of measure. Maintain a material master record. Archive and delete a material master record. Use classification to search for a material number.
The material master contains information on the materials that a company constructs, procures, manufactures, stores, and sells. The information is stored in a database that is a central source of data on materials. The material master record integrates data from different areas of a company.
Material master record SAP AG 2003
For the company, the material master record represents the central source for data on materials. The material master is used by various R/3 logistics applications. The material can be a finished product (product, article), a semi-finished product (subassembly), or a raw material (purchased part).
Plant: Definition A plant is an organizational unit within a company. A plant is a place where valuated goods and services are: Manufactured Stored Consumed Distributed
A plant can be used to define a: Manufacturing facility Central storage facility Corporate headquarters Sales office
Organizational Structures and Plants Client Client Controlling area 1000
Company code 1000
Controlling area 1200
Company code 0001
Company code 0002
Valuation area 1000
Valuation area 1100
Valuation area 1200
Valuation area 0001
Plant 1000
Plant 1100
Plant 1200
Plant 0001
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Organizational units are tightly linked to each other to quickly process the relevant data for a business area. For example: Plant 1000 is assigned to a company code 1000. Company code 1000 is assigned to controlling area 1000. Therefore whenever a transaction involving cost occurs in plant 1000, the relevant records in controlling area 1000 are automatically updated. The valuation area is the organizational level at which material quantities and values are managed. It is essential for product costing that a valuation area exists for each plant. Within each valuation level, you can differentiate between values and quantities for valuation (inhouse production and externally materials) by using different valuation types. In Customizing for materials management, (define valuation type), balance sheet valuation is set up at company code level or valuation area level. Selection of valuation area level automatically causes the creation of a valuation area for each plant. In order to use product costing and order costing, inventory must be valuated at plant level.
Organizational Levels for the Material Master Record
Material
General data
Client
Material number Description Units of measure Technical data
PlantPlant-specific data
Plant
Storage location
MRP data Work scheduling data Purchasing data
Stor. locationlocation-specific data
Data in the material master record has a hierarchical structure which covers the following organizational levels: Client, plant, and storage location The hierarchical structure of the data makes it easier to organize information on materials throughout the company and minimizes data redundancy. Engineering data is managed mainly on a client level.
Stock quantities
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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 clogging up your data with redundant information, the material master is structured hierarchically, in such a way that a company's structure is reflected in it. Data on client level General material data that applies to the whole company is stored on client level. This includes material descriptions, base units of measure, and conversion factors for alternative units of measure. 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 forecasting data. 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.
Material master records are grouped according to industry sector and material type.
Raw materials Raw materials
Semifinished products
Semifinished products
Finished products
Finished products
Other
Other
The industry sector determines which industry-specific data appears in the material master record. The material type determines which departments can enter data and whether quantities and/or values are updated in inventory management.
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When you create a material master record, you must define the industry sector and material type for the material. The industry sector determines which data fields and screens are available for input during material master maintenance. The material type determines which R/3 business processes (such as sales, production, and purchasing) and functions (use of material in BOM or routing) are allowed for a material. The person who creates the first view of a material master record defines: The material number The industry sector The material type The unit of measure The description
The industry sector determines which branch of industry the material is assigned to. The industry sector determines:
Industry sector Description of Industry Sector A C M P
Aerospace & Defense Chemical Industry Mechanical Engineering Pharmaceuticals
Which screens appear and in which order Which industry-specific data appears
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Besides grouping together materials as different material types, you must also assign a material to a specific branch of industry. You do this by specifying the industry sector when you create a material master record. If necessary, you can predefine this field and hide it.
Material Type A material type groups together materials that have attributes in common. The material type controls: Which departments (views) can maintain material master records Whether and how quantities and values are updated in the system Whether internal or external procurement is allowed
Material type
Which G/L accounts (for example, material stock account) are updated
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So that you can manage different materials according to the company's standard requirements, materials with the same characteristics are divided into groups and assigned to a material type. Examples of material types are: raw materials, semifinished products, and finished products. 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 can enter Whether quantity changes in the material master record are updated Whether value changes are updated to financial accounting stock accounts Additionally, the material type determines the procurement type of a material. For example, whether the material is produced in-house, procured externally, or both. Moreover, the material type determines which accounts are posted to when a material enters or leaves the warehouse.
Definition The material master record is a central data object in SAP R/3. It is used to model raw materials, auxiliary materials, semifinished products, products, and production resources and tools
Since the material type influences internal processing, the system checks which changes are allowed. You can change the material type without restriction if no stocks, reservations, or purchasing documents exist. If stock, reservations, or purchasing documents exist, the material type can be changed if: The same G/L account is updated as by the old material type. Quantities and values are updated as they were by the old material type.
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For further conditions refer to the documentation.
The material master record is used by all R/3 logistics applications. It controls whether a material is bought, manufactured and/or sold. Every business function can maintain one or more views of the material master. Because 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. Data maintained in the following views is used by production planning functions: The basic data view contains general data such as the material number, the material description, base unit of measure, and technical data. The classification view contains user-defined class assignments for a material. The MRP view contains plant-specific data used in the planning of materials for production or procurement. The work scheduling view contains plant-specific data used in the scheduling of materials for production.
There is a standard sequence for the data screens on the main working level. You can interrupt this standard sequence at any point to go directly to any other screen. To see the screens on the additional data level, choose the Additional data pushbutton. Using the appropriate pushbuttons you can also branch from the main working level to secondary screens: Example: Accounting View 1 Pushbutton:
Material number Multilingual descriptions Base unit of measure Cross-plant material status Size, weight, and other dimensions Drawing data (design documents) Indicator: Material is configurable
Class type - 001 (Material) Class Characteristic values
MRP View
Work Scheduling View
Procurement type MRP type (MPS, MRP, other) Planning strategy Lot size and safety stock Indicator: Backflush MRP controller and MRP group Assembly scrap and component scrap In-house production time Indicator: Repetitive manufacturing
Unit of issue (base unit of measure) Production scheduler Indicator: Batch management reqmt Delivery tolerances In-house production time Inspection stock indicator Default storage location for GR/GI Plant-specific material status
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The basic data view consists of frequently used basic information which can be used by all business functions and processes. The units of measure, dimensions, and configurable material indicator are used in bills of material and routings. Classification data is part of the general material data. The characteristic values are used to find several materials that share a common attribute. MRP data is plant specific. The backflush indicator, assembly scrap, and component scrap values are also used in BOMs and routings. Work scheduling data is plant specific. The unit of issue and base units of measure are used in BOMs and routings. The lot size-dependent in-house production time in the work scheduling view can be updated from the material's routing data.
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. 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. Note: As of R/3 4.6, you can select the Create Views Selected checkbox, which automatically creates all views that exist in the reference material. Previously, each view (department) had to be viewed. This is no longer required.
To access material master data efficiently, you can: Predefine the industry sector Predefine the selection of views Predefine the selection of organization levels
To enable more efficient and accurate entry of MRP / forecast data, you can predefine MRP / forecast profiles Define MRP profile / forecast profile: Default values for MRP / forecast data fields Rules for MRP / forecast data field input
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The MRP profile allows users to set default values for MRP data fields and determine whether the values can be changed during material master maintenance. If a change is made to a default value in an MRP profile and the field cannot be changed by using material master maintenance, the system automatically changes the field value in all material masters linked to that specific MRP profile. The forecast profile allows users to set default values for forecast data fields and determine whether the values can be changed during material master maintenance. If a change is made to a default value in a forecast profile and the field cannot be changed by using material master maintenance, the system automatically changes the field value in all material masters linked to that specific forecast profile.
Each material has a unique material number to identify it. You can assign a number externally or internally. If you assign a number externally, you enter the character string you require when you create a material master record. If you assign a number internally, you do not enter any material number when you create a material master record. The internal number is shown in the material number field, but is not saved to the database until you save the material. The type of number assignment that is allowed depends on the material type and is defined in Customizing. First, you have to maintain the number range groups. You then assign the material types to the groups. You can assign an interval to only one group. You can change the current number of an interval manually.
Database Material number: 18 Characters Conversion Input/output length Leading zeros Template Storage type SAP AG 2003
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 unconverted. Caution: The display format for the material number is effective for all clients.
In addition to the base unit of measure that the system uses for stockkeeping and to execute all its calculations, other departments can use their own units of measure. All units of measure in R/3 that are additional to the base unit of measure are grouped together under the title "Alternative units of measure". The following alternative units of measure are supported: Base unit of measure: Stockkeeping 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. Order unit: Unit of measure used for ordering the material. This is the default unit that is displayed in purchasing functions. Sales unit: Unit of measure used for selling the material. This is the default unit that is 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 transactions. You can enter use this unit for the BOM item quantity. The engineering department usually uses the base unit of measure.
Input transaction: Conversion factors to base unit of measure are known SAP AG 2003
You can group together several units of measure in a unit of measure group and assign them to a material. For each unit of measure in the group, you can enter the conversion factor to the base unit of measure. You maintain unit of measure groups in Customizing for the material master (Logistics - General). Note: The base unit of measure must not be entered in the unit of measure group.
Purchasing BOM header BOM item Routing Independent requirements Forecast MRP Production order header Production order item PRT
Warning Error X
X X X X X X X X X
Plant maintenance
X
Inventory management
X
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The material status allows you to control where a material can be used in business applications. You define the material status in the material master record in accordance with the material, client, and plant. You can limit the use of a material in different ways: The material can be flagged for deletion. The material status can lock the material for certain business processes in materials management and production planning, You can display and check 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: Choose Information on material from any screen. You can define the material status for all plants (basic data view), or separately for each plant (plant view). Note: The more restrictive status has priority (regardless of whether it is the cross-plant status or the plant-specific status).
Allows you to extend the material master record by adding further views. 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? Important maintenance statuses: Department:
Maintenance status:
Work scheduling A Accounting B Classification C MRP D Purchasing E Production resources/tools F Costing G Basic data K ...and so on (see maintenance status in transaction MM50: Extend Material Views) Note: If additional views are to be added to an existing material master record, you can also work with the create material function.
This function allows you to create lists of materials according to specific, combinable selection criteria: List by material numbers List of all materials that have been created in certain plants List of all materials of a certain material type List of all materials that have been created by a specific user
You can flag materials for deletion by setting the deletion flag in the material master record. The materials to be deleted can be determined by the system by using a proposal list.. The deletion flag can be scheduled in the future and must then be activated at the correct time. All records flagged for deletion are deleted by a reorganization run, provided that they are no longer used - as a BOM header, for example. 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 Note: System checks are performed during reorganization to ensure that deletion and archiving of the material is allowed.
You can archive material master records. The data is stored in a sequential file (archive file). Archived data can be deleted from the database by using the deletion program/reorganization. Archived material master records can be displayed, but they cannot be retrieved. Archiving and reorganization are handled in detail in the administration courses.
The functions of the classification are: To find an appropriate object To find similar objects To establish that no appropriate object exists To fulfill these objectives, you need to organize your data efficiently. The classification in SAP R/3 is a tool for organizing your data that goes far beyond matchcodes and systematically structured number assignment. The four parts of R/3 classification are: Characteristics maintenance Class maintenance Classification (assignments) Object search Course PLM130 contains more information on classification in SAP R/3.
An object is a classifiable unit (such as material, supplier, work center, customer, and so on). A class is a name for a group of objects that have common or similar attributes. A characteristic describes attributes of an object (such as length, industry standard, and basic material). A characteristic value represents the specification of a particular attribute. (For example: 10 cm, DIN 931, or cast iron.) The procedure for class maintenance is as follows: 1. Define characteristics and allowed characteristic values 2. Maintain the class and assign the characteristics to it 3. Maintain the objects (for example, materials), assign them to one or more classes, and assign values to them 4. Find objects
Finding a Material What is the number of the material?
List of classes
Display material master Material _____
Display material master Material P-105
Oils List of classes Pumps Tools
List of materials
Characteristics
P-103 P-105
Pump height: 10 m Turning speed: 1000 Material: Steel
10 10
Steel Steel
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SAP R/3 classification makes it easy for you to find objects (for example, materials). If you have set up classification, you can use it to find a material number and copy the number to your application.
Example: <20 up to and including 20 Example: >14 from 14 upward
Combination
<10; 17; 19 - 23; >30
Comparison type
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
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You can use characteristic values in various ways when using classification to determine a material number. 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.
You are now able to: Maintain different organizational levels for a material Control the processing of materials by using material type, industry sector, and material status Carry out number assignment internally or externally Recognize that material master data is divided into different user departments (views) Use the Extend material views function, which allows you to maintain further views (in addition to the create function) Use R/3 classification to classify materials. This enables you find materials more easily.
Data Sheet for Exercises Explanation of the Symbols used in the Exercises and Solutions Exercises Solutions Course Objectives Business Scenario Hints and Tips Warning or Caution Note: There may not be sufficient time to work through all the exercises during the course. The exercises marked Optional should be seen as supplementary examples that can be used, as required and time permitting, during the course. Course participants can also use these exercises after the course, to consolidate what they have learned.
At the conclusion of these exercises, you will be able to: • Display a material master record
A design engineer displays a material master record.
1-1
Display material master record T-F1## (## = group number). 1-1-1 Change the default settings for further processing as follows: Industry sector: Mechanical Engineering Hide the industry sector on the initial screen Views:
Basic Data 1 and 2 MRP 2 and 4
Organizational levels:
Copy from:
Plant: Storage location:
1000 0002
1000 0002
1-1-2 Write down the entries you see for: Base unit of measure
___________
Material group
___________
Laboratory/office
___________
What does this abbreviation mean?
___________
Procurement type
___________
1-1-3 From the material master record, display an original document belonging to the material. (Enter front-end type TR or PC if prompted). 1-1-4 When and by whom was the data created? (See icon I)
At the conclusion of these exercises, you will be able to: •
Create a material master record using a reference material and classification.
• Extend and classify a material master record A finished product is created in the group, and plant views are added to it.
1-2
Create the following material master record by copying from a reference material: A finished product (FERT) with material number T-F## (## = group number) in plant 1000, storage location 0002, copied from material T-F1##, with the following views: Basic Data 1 and 2 MRP 2 and 4 1-2-1 Enter material number T-F## and use the classification system to find the material to Copy from as follows: Tab page:
Materials for class
Class
100 with keyword Pump*
Class type
001 (material class)
Characteristics and their values: Pump height: 10 m Pump capacity: 20 m³ Turning speed: 1,000 Copy material master record T-F1##. Note the maximum number of hits. This means that the material you are looking for may not be in the hit list. Check your user settings. Extras → User settings: Tab page Find object Field: Maximum hits (increase value to 200 or 500)
1-2-2 Which views are selected? ______________________________________________________ ______________________________________________________ You want to ensure that you are creating a material for plant 1000, storage location 0001. To do this, choose Organizational levels. Change the description of the new material to Pump ## (## = your group number. View all the selected views before you save. Ignore any warning messages.
1-2-3 What happens if you do not view the views? In other words, if you do not confirm each view before you save? ___________________________________ 1-2-4 How can you add missing views to a material master? 1-2-4-1__________________________ 1-2-4-2__________________________ 1-2-5 How can you avoid having to confirm each view when you create a material? (New as of R/3 4.0) ___________________________________ 1-3
Create another material master record as follows: A semi-finished product (HALB) T-B##, copied from material T-B1## in plant 1000, with the following views: Basic Data 1 and 2 MRP 2 and 4 Change the description to Casing ##. Enter the material number of reference material T-B1##.
Delete the default settings for views and organizational levels that you created in the first exercise.
1-5
Create a third material master record for finished product T-GR## with the view Basic Data 1: Description: Demo – Group ## Base unit of measure: PC
1-6
Extend this material master record using the function Extend material view(s) by adding view: MRP Enter values of your choice (maintain the REQUIRED data fields). (On the selection screen, enter only the material number T-GR##.)
1-7
Flag material master record T-GR## for deletion.
1-8
Create a Classification view for the other material master record T-F1##. Class type: 001 Class: 100 Pumps Characteristics: Pump height: Pump capacity: Usage:
Material class 10 m 20 m³ House technology
1-9
Extend the semi-finished product T-B1## using the function Extend material view(s) by adding view Work Scheduling. In the Unit of issue field, enter: PAL (Pallet) In the dialog box you see, enter the conversion factor between pallet and piece. Example: 1 PAL contains 5 PC
1-10
Change the finished product T-F## (## = group number): View: Basic Data 1: Under General Data, in field X-plant matl status, enter: ZS (locked for BOM items)
Display material master record: Logistics → Production → Master Data →Material Master→ Material → Display → Display Current or Logistics → Central Functions → Engineering→ Material → Material → Display → Display Current or Logistics → Materials Management → Material Master→ Material → Display → Display Current 1-1-1 Enter material number:
T-F1##
Defaults Industry sector: M Select Hide industry sector on initial screen Views: Basic Data 1 Basic Data 2 MRP 2 MRP 4 Select View selection only on request Copy from: Organizational levels: Plant: Storage location:
1000 0002
1000 0002
Select Org. levels/profiles only on request 1-1-2 Basic Data 1:
Base unit of measure: Material group: Lab./office: Description:
PC 001 KB1 Construction Office KB1
MRP 2: Procurement type:
E (In-house production)
PLM110
2-43
1-1-3 Choose pushbutton Additional data then tab Document data Select and display a linked document and its originals: Icon: Display originals (If prompted, enter front-end type TR or PC.) 1-1-4 In addition to the material number and description: I Icon: (Information on material)
Solutions Unit: Material Master Record Topic: Material Master Maintenance
1-2
Create material master: Logistics → Production → Master Data → Material Master → Material → Create (Special) → Finished Product or Create (General) → Immediately (Material type FERT) or Logistics → Central Functions → Engineering→ Material → Material → Create (Special) → Finished Product or Create (General) → Immediately (Material type FERT) or Logistics → Materials Management → Material Master→ Material → Create (Special) → Finished Product or Create (General) → Immediately (Material type FERT) 1-2-1 Use classification to find the reference material. Choose the search help in the Copy from "Material" field. Tab page: Materials for class Choose search help in field Class. Keyword: Enter pump*. Select class 100, class type 001. Characteristics: Pump height: 10m Turning speed: 1,000
Pump capacity:
20 m³
Pushbutton: Find in initial class Copy material master record T-F1## (## = your group number). Ignore any warning messages and view all of the chosen views, before you save. 1-2-3 What happens if you do not view the views? In other words, if you do not confirm each view before you save? The views (departments) are not created.
1-2-4 How can you add missing views to a material master? 1-2-4-1Material → Create (Special) or Create (General) → Immediately (MM01) 1-2-4-2... Material Master → Other → Extend Material Views (MM50) 1-2-5 How can you avoid having to confirm each view when you create a material? (New as of R/3 4.0) Defaults: Views
Select: Create views selected
1-3
Procedure as for exercise 1-2. Exceptions: Material type HALB (semi-finished product), reference material TB1##.
1-4
Defaults Delete all default settings for views and organizational levels. Procedure similar to 1-1.
1-5
Procedure as for exercise 1-2. Exceptions: Material type FERT (finished product), without reference material.
1-6
In the material master menu Others → Extend Material View(s) Enter selection parameter material T-GR## on the selection screen and execute. Select the line with the status D and choose pushbutton Maintain materials. Enter plant 1000, maintain the view with any values (your choice), and save .
1-7
In the material master menu, choose Flag for Deletion → Immediately. On the selection screen, selection parameter material T-GR## and set the deletion indicator.
1-8
Procedure as for 1-6, maintenance status C, or: Create Material→ Immediately, with the material that already exists. Select the Classification view.
1-9
or From the material master menu, choose Create Material (General) → Immediately Select view: Work Scheduling Enter a Unit of issue such as PAL (Pallet) In the dialog box you see, enter the conversion factor between base unit of measure and the alternative unit of measure.
1-10
From the material master menu, choose Material → Change → Immediately. View: Basic Data 1: Under General Data, in field X-plant matl status, enter:ZS (locked for BOM items)
At the conclusion of this unit, you will be able to Name the basic terms we use for bills of material Create bills of material on client level and plant level Distinguish between BOM category, BOM usage, and validity Name and use the different item categories in a bill of material Distinguish between BOM status and item status
Your company has a central engineering department. You create group BOMs and assign them to different plants. You add various item categories to the BOMs. You use classification to find materials.
Bill of material A bill of material is a complete, 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.
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BOMs and routings contain important basic data or master data for integrated materials management and shop floor control. In the engineering department, new products are designed to be suitable for production, as well as for their intended function. The result of this product phase is drawings and a list of all the required parts, the bill of material (BOM). BOMs can be found in various forms wherever finished products or semifinished products are produced from several component parts or materials. Depending on the industry sector, they may be called: Recipe List of ingredients
Bill of material Single-level BOM Assembly Part 1 Part 2 Part 3
Item 1 Item 2 Item 3
Part n
Component 1 Component 2 Component 3 Component n
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Assembly: An assembly is a set of components for a product that belong together for production purposes. The assembly can itself be used as a component in another assembly. Single-level BOM: A single-level BOM is a set of all the components that represent one or more assemblies. Component, part, and item are synonymous terms.
Bill of material Routings Classes PRTs Work center
Production MRP
Warehouse
Plant maintenance
Planned orders Production orders
Maintenance plan Maintenance order
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Data that is saved in BOMs forms a significant basis for various areas within production planning. The engineering department creates BOMs. You can create BOMs in R/3 using a CAD program and a CAD interface. Material requirements planning (MRP) explodes BOMs in order to determine economical order quantities at a particular point in time. In work scheduling, BOMs form the basis for the planning of operations and shop floor control. Production order management uses BOMs to plan the provision of parts. 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 for a product The simultaneous use of BOM data in several areas 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.
BOM categories define the connection to an object. Material BOMs are used to represent the structure of products that are produced within the company. Order BOMs are used to produce a product for a specific sales order. A document structure can consist of several documents, for example, a program, technical drawings, paper documents, and photographs. You need document info records for these. 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. Functional location BOMs are used in plant maintenance to link equipment to specific locations.
Does a material master exist for the BOM header? What is the BOM going to be used for? Is this material type allowed in BOMs? In which plant is the BOM required? When does the BOM need to become effective? Are change documents necessary? Does the material belong to a BOM group? What status does the BOM have? Are there default values?
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The questions listed above must be answered before you create a bill of material.
The following default values are defined in Customizing: Base quantity for bills of material BOM status Settings for item category R (variable-size item)
The following default values can be defined by the user, or defined per user in Customizing: Item increment Item category Material provision indicator Various BOM reporting options
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You can use default values to make data entry more efficient. Each user can also define their own default values to optimize or simplify data entry. These settings can also be defined per user in Customizing.
Definition A bill of material is a comprehensive, formally structured list of the components that make up an object. The list contains a description and object number for each object, together with the quantity and unit of measure.
Examples Item
Item cat. Material
Quantity
Unit
10
L
Material 1
100
piece
20
L
Material 2
10
grams
30
L
Material 3
1
meters
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Note: The system proposes the base unit of measure from the material master record as a default unit. However, if the alternative unit of measure unit of issue is maintained in the Work Scheduling view, this can be used. However, this uses the conversion factor between base unit of measure and unit of issue, which must be entered when you maintain units of issue.
The usage allows you to create separate BOMs for the various areas within the company, for example, engineering or production. The engineering BOM combines all the components of the product from the engineering point of view of and contains all the technical data. The production BOM is set up from the production point of view. For example, process data is required for assembly. The costing BOM is the basis for the automatic calculation of the material usage costs of a product. Of course, you can also work with just one BOM for all areas by using the item status to cover all possible differences. When creating BOMs with different usages for one material, the system saves each BOM usage under its own internal number. The usage is read by the authorization checks for BOM maintenance. Note: The BOM usage controls which item statuses are available, but detailed control features are set up in the individual item (on the item detail screen).
To define the precise conditions under which a bill of material must be used by different areas in a company, you define an area of validity and a validity period. The area of validity defines which plants can use a bill of material. You can extend the area of validity by assigning the same bill of material (with the same internal BOM number) to a material 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 (plant assignments). There must be a plant view for the BOM header and all the item materials in each plant that the BOM is assigned to.
Material BOMs can be valid on different organizational levels: A material BOM can manage data that is directly relevant to production. In this case, the area of validity is the plant. The plant is a place of work where all the necessary work scheduling activities are organized, for example: Planning material requirements Creating routings In this case, you create a plant-specific BOM. You can also create a BOM without reference to any plant - a group BOM. This is useful, for example, if a design engineer maintains a BOM during the engineering phase. The group BOM can be made effective for individual plants by using the plant assignment function.
Plant-specific BOMs are independent of each other. In other words, a separate BOM structure exists for each plant 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.
The validity period is the time during which the BOM is valid. This period is defined 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 change number, the system copies the valid-from date from the change master record. Valid-to date This date marks the end of the validity period for the BOM item. The system calculates this dynamically. Note: The system assigns a default valid-to date of December 31, 9999. If you change a bill of material with a change number that has a valid-from date, the validity period of the previous state of the object ends at 0.00 hours on that date. You can define a valid-from date for an entire BOM and for individual items.
When you create a BOM, a low-level code is automatically assigned to each material. This is used in MRP and costing. You can display the administrative data in the material master record to find out the low-level code for a material. Low-level coding is used in material requirements planning (MRP) to determine the sequence in which materials are planned. 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. The low-level code is the lowest explosion level on which a material occurs in all product structures. Low-level coding collects the total requirements for a material on the lowest explosion level where it is used.
Status Texts Lot size ... Status Scrap Texts Recursion ... Quantities Installation point ...
2) Subitem . . .
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The large amount of data required in a bill of material is managed in structured form: You maintain data that applies to the entire BOM in the BOM header. You maintain data that applies to an individual component in an item. Items can be divided into subitems if partial quantities have different installation points. Subitems have no control functions.
Subitems represent different installation points for partial quantities of an item. For every subitem, you can also maintain a short text next to the subitem quantity. The sum of the subitem quantities replaces the item quantity. A subitem has no control functions in the BOM. This means, for example: - Assignments to operations in routings are defined only at the item level. - Scrap is calculated only at the item level.
- Engineering - Production - Plant maintenance - Spare parts - Sales - Costing
Exception message History requirement SAP AG 2003
The BOM status controls BOM processing in different application areas. When you configure your system in Customizing for bills of material, in activity Define BOM status, you define the statuses for different indicators that allow or disallow BOM processing. Examples: 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. When you configure your system in Customizing for bills of material, in activity Define BOM Usages, 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 application area in your company.
Stock item NonNon-stock item VariableVariable-size item Text item Document item Class item PM structure element Intra material
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When you create a new BOM item, you must specify an item category for each item. The item category defines the features and functions of an item. The item category identifies whether special data must be processed, and it controls further system activities. The item category addresses the following questions, for example: Must a material be entered? Does the item support quantity-based inventory management? Are both plus and minus signs supported? Are subitems supported? Which screens are selected and how does the screen layout of the item detail screens look? Note that you cannot change the item category after you have entered the item. You can only correct an entry for the item category by deleting the item and then creating a new one.
Items 40 and 50: Purchasing data - Price - Price unit - Cost element
- Material group - Purchasing group - Delivery time
Fields relevant to MRP and costing
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You can create non-stock items both with and without a material master record. If you create a nonstock item without entering a material number, you must enter a descriptive text and purchasing data. Using the price data (purchasing data) entered, the system calculates the release strategy. The material group is necessary for creating a purchase requisition. The component is procured directly for the production order. Purchase requisitions are created automatically.
Different dimensions, up to 3 sizes Variable-size item data determines the component quantity
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Enter this item category to represent different sized pieces of a material under one material number. On the item detail screen for variable-size item data, the system calculates the variable-size item quantity from the sizes specified and the formula specified, if any. Advantages: Material requirements planning can be executed without any additional work steps, by using the BOM explosion. You do not have to create a separate material master record for each size you cut. All calculations use the variable-size item quantity.
Entering a formula for calculating the quantity of a variable-size item allows you to execute complex calculations. You must maintain these formulas in Customizing. If there is no formula key, the system multiplies the sizes: Size 1 * Size 2 * Size 3.
Use this item category if you want to document the product or a component. Prerequisite: A document info record exists for the document, maintained in R/3 document management. The document info record contains basic information for integration into the business process, for example, information about the processing state and the storage location. Depending on the document type, you can manage various types of document data (such as technical drawings, photos, or texts). You can use these documents to describe an object comprehensively. You can display the document on the screen. You can find out more about SAP R/3 document management in course PLM120.
A class item has characteristics and is used in configurable BOMs. You can use classes that have materials or documents classified in them (with class types 200, 201, and 300) as class items. When you configure a BOM, the class node can be replaced by a specific material or document.
A BOM is recursive if the product contains a component that has the same object number as the product. Recursion may be an error, but it can also be intentional. If the system recognizes the recursion online, you see this message: Error: BOM is recursive In exceptional cases, recursion can only be recognized by the update program. The person who creates the recursive BOM receives a message. If you want to create a recursive BOM, set the Recursion allowed indicator in the BOM item.
The various item categories can be combined with various indicators. This covers many special procedures. Screens: B = Basic data S = Status/lng text You can set most control indicators in the material master. Most are not copied to the BOM. You can make settings for MRP data on the basic data screen for the BOM item that override the indicators in the material master record: Switch off phantom assemblies Individual requirements indicator Direct production (special procurement key SOBSL 52) Long-term planning
You can delete bills of material by using: The deletion function Deletion flags
You can: Delete the entire BOM Delete individual items
BOMs can be deleted: Without history With history using engineering change management
Authorization groups control who can delete a bill of material
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Using the deletion function removes the BOM immediately or on the valid-from date of the change master record. If you set the deletion indicator in the BOM header, the BOM is deleted during the next reorganization run. Deletion at the header level removes the entire BOM, whereas deletion at the item level removes only the item specified. If you delete a BOM without history (without a change master record) the deletion is carried out immediately. Once the deletion has been executed, you can create a new BOM with the same material, plant, and usage. If you delete a BOM with history (with a change master record) the system deletes the bill of material on the valid-from date of the change master record. Before deleting a BOM, the system checks for: Items with object dependencies to check whether the change master supports maintenance of dependencies for configurable BOMs. Items with operation assignments. If assignments exist, the system displays the relevant message. See the SAP Library for more information.
Monitoring und documentation of changes Planning and execution at a specific point in time Saving of several change states of the same object Integration in the supply chain Collation of changes that belong together For different objects For the same or different points in time With special comprehensive documentation
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Engineering change management in R/3 is a central logistics function that can be used to change various master data and document the changes. 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. You can use engineering change management to store R/3 objects (for example, BOMs and routings) more than once. This means that the objects can be stored in all relevant change states. The changes take effect automatically at the predefined time right across the supply chain, for example, in the sales order, material requirements planning, and shop floor control. You can use engineering change management to group together changes to different R/3 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. You can use engineering change management to fulfill your legal obligations to document changes.
You can make object changes (for example, BOM changes and routing changes) in SAP R/3 either with or without history. However, you should be aware that change documents are created by the system, even for changes without history. Changes 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 state of the object before the change is not saved. You can only find out about the status of the object before the change indirectly, by using change documents. Changes with history These are changes that must be documented because they take place during production, for example. Both the state before the change and the state after the change are saved. In addition, the system creates change documents. For some objects, these change documents differ from those created for changes without history. Engineering change management in R/3 enables you to document changes completely, to cover product liability requirements, for example.
As of R/3 4.0 you can define validity by serial number. You can define the validity of an assembly as depending on the serial number of a specific finished product. You can define this effectivity type for the serial number of a specific finished product or for a range of serial numbers. If you want to define validity according to serial numbers, you must use engineering change management.
Effectivity Types: Time Interval BOM for pump from January 1 until June 30 Change no. Effectivity: Time interval 01/01 – 06/30
1
30
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As of R/3 4.0 you can define validity by time interval. You can define the validity of an assembly for a period of time with an upper and lower limit. If you want to define validity according to time intervals, you must use engineering change management.
Bill of material for customer Change no. Effectivity: Customer B
Change no. Effectivity: Customer A
Change no. Effectivity: Customer C
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As of R/3 4.0 you can define your own company-specific effectivity types. You define parameters, such as customer or airline, which you link to a data element. You can use the assigned parameter type to enter single values or open intervals. You can combine the different effectivity types. This means that you can define the effectivity of a bill of material as "customer A and serial numbers 1-10" or "customer B, serial number 11", for example. If you want to use company-specific effectivity types, you must use engineering change management.
You are now able to: Create a bill of material for a material, plant and usage, and define the circumstances under which it is valid. Use different item categories to control further system activities. Use the BOM status to control BOM processing in different application areas.
At the conclusion of these exercises, you will be able to: • Create a group BOM and assign it to other plants • Create, change, and display BOM basic data The engineering department creates a group BOM. This BOM is to be made effective in other plants by using plant assignments. Because the structure of the BOM in plant 1000 is not identical to that of the group BOM, a plant-specific BOM is maintained in this plant.
1-1
Set the default settings for your user so that the item increment is 10. These should be the default settings. When you create a: Material item Item category L Document item Item category D
1-2
Create a group BOM for material T-F## (## = group number). Note the following when you create a group BOM: Plant: (group BOM has no entry for plant) BOM Usage: 1 (Production) Alternative BOM: No entry Today's date Valid from: 1-2-1 Which system message do you get, and why? (only if material status ZS is assigned) 1-2-2 Enter the following items for BOM T-F##: Item Item cat. Component Quantity Sort string 10 20 30
material group. Do not exit the current transaction and do not create another session. What is the name of the material group? 1-3
_________
Assign the group BOM to plants 1000 and 1100. 1-3-1 Why can you not assign it to plant 1100? ______________________________________________________ 1-3-2 Go to the BOM header for plant 1000. What is the internal BOM number?
_______________
Why?
_______________
1-3-3 Explode the plant assignment (plant 1000) and create a plant-specific BOM for T-F## in plant 1000. Use the group BOM as a template. In item 10, replace assembly 100-100 with material T-B##. Change the component quantity of item 20 from 2 to 1. Which components are assemblies themselves? ______________________________________________________ Maintain item 20 as a spare part with indicator A. (See icon Item or key F7) Sort bill of material T-F## (plant 1000) according to the sort string. 1-4
Create assembly T-B## in plant 1000 as follows: Item 10 20 30
Item cat. L L L
Component 100-110 100-120 100-130
Quantity 1 1 1
1-4-1 What is the status of the bill of material?
_______________
Does this status allow the BOM to be used in costing? _______________ 1-4-2 In the appropriate field, enter Construction Office KB1 as being responsible for the BOM (header: further data). Save your BOM.
At the conclusion of these exercises, you will be able to: • Process further BOM items according to item category
The plant-specific BOM is extended by adding different items according to requirements.
1-5
Extend your plant-specific BOM T-F## in plant 1000 from the previous exercise by adding the following data: 1-5-1 Item 40
Item cat. L
Component 100-600
Quantity 2
The 2 support bases are mounted on the pump. Two support bases: One support base is to be mounted at the front of the pump and one at the back of the pump. Create subitems for this. 1-5-2 Item 50
When using Universal usage, which fields are set as required fields?
PLM110
3-40
BOM Management Solutions
1-1
Unit:
BOM Management
Topic:
Basics of Bills of Material
Set defaults for user: Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Create or Logistics → Central functions → Engineering → Bill of Material → … → Create and Logistics → Production → Master Data → Bills of Material → Bill of Material → Material BOM → Change or Logistics → Central functions → Engineering → Bill of Material → … → Change Then: Settings → Current settings → User-specific settings: Icon: Execute
