Scm340 en Col52 Fv Part a4

SCM340 Process Manufacturing

Date Training Center Instructors Education Website

Participant Handbook Course Version: 2005 Q2 Course Duration: 5 Day(s) Material Number: 50073626

An SAP course - use it to learn, reference it for work

Copyright Copyright © 2005 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. Additionally this publication and its contents are provided solely for your use, this publication and its contents may not be rented, transferred or sold without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors.

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

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About This Handbook

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Icons in Body Text The following icons are used in this handbook. Icon

Meaning For more information, tips, or background Note or further explanation of previous point Exception or caution Procedures

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Contents Course Overview ......................................................... vii Course Goals ...........................................................vii Course Objectives .....................................................vii

Unit 1: Introduction........................................................ 1 SAP Solutions and Components for Representing the Process Chain with In-House Production...................................3 Order-Controlled Production using Process Orders.............. 10

Unit 2: Order Structure and Processing ............................ 41 Process Order Structure and Elements ............................ 42 Process Order Processing ........................................... 56

Unit 3: Order Creation .................................................. 71 Order Creation ........................................................ 73 Master Data Selection................................................ 90 Scheduling ............................................................144 Costing ................................................................163

Unit 4: Process Planning and Order Release .................... 173 Process Planning ....................................................175 Material Availability Check ..........................................177 Batch Determination .................................................218 Batch Determination and Material Quantity Calculation ........270 Resource Reservation...............................................292 Order Release ........................................................319

Unit 5: Principle of Process Management (I) ..................... 353 Principle of Process Management (I)..............................354

Unit 6: Material Staging and Withdrawal .......................... 363 Material Staging Options............................................364 Goods Issue Posting ................................................372

Unit 7: Confirmations .................................................. 405 Confirmation Procedures ...........................................406 Confirmations and Material Movements ..........................447

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Unit 8: Goods Receipt, Order Settlement, and Order Archiving.................................................................. 473 Goods Receipt .......................................................474 Order Settlement .....................................................506 Archiving and Deleting ..............................................523

Unit 9: Principle of Process Management (II) .................... 531 Process Management - Overview .................................533 Process Instructions, Control Recipes, and Process Messages .........................................................536 Link to Process Control Systems ..................................591 Elements of PI sheets ...............................................596 Manufacturing Data Access ........................................607 SAP OPC Data Access .............................................610

Unit 10: Process Data Evaluation ................................... 621 Process Data Evaluation............................................622

Unit 11: Production in Compliance with GMP .................... 637 Production in Compliance with GMP - Overview ................639 Digital Signature......................................................642 Approved Process Orders ..........................................677 Material Identification and Material Reconciliation...............692 Integration with Quality Management .............................707 Batch Record .........................................................732 Batch Derivation......................................................748

Unit 12: Appendix: Integration with Production Planning .... 767 Overview of Planning Functions and Planning Elements.......768 Planning and Conversion of Planned Orders in the SAP ECC System.............................................................771 Planning and Conversion of Planned Orders in the SAP SCM(APO) System ..............................................787

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Course Overview This training course teaches you about the application of process orders.

Target Audience This course is intended for the following audiences: • •

Members of the project team responsible for implementing process orders in production (consultants, organizers). Managers and employees in production areas (work schedulers, production schedulers, foremen, workers).

Course Prerequisites Required Knowledge • • •

Knowledge of PPC SCM300 (Supply Chain Manufacturing Overview) PLM115 (Basic Data for Process Manufacturing)

Recommended Knowledge • • • • •

SAPSCM (mySAP SCM Overview) SCM100 (Planning (ERP) Overview) SCM200 (Extended Planning (SCM)) SCM240 (Production Planning (ERP)) SCM250 (Production Planning and Detailed Scheduling (APO PP/DS))

Course Goals This course will prepare you to: • • •

Use process orders Make important system settings for executing process orders Acquire knowledge on other selected topics relating to process manufacturing

Course Objectives After completing this course, you will be able to: • • •

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Explain where process orders fit in within the Supply Chain Management Carry out the individual steps of process order management Use the main order management functions


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Course Overview

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• • •

Make important system settings Take integration relationships into account Learn about further special functions by studying on your own

SAP Software Component Information The information in this course pertains to the following SAP Software Components and releases: •

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Unit 1 Introduction Unit Overview Topics: • • • •

SAP solutions and components for representing the process chain with in-house production Integration between manufacturing and planning Production types Order-controlled production using process orders

•

– Application areas – Characteristics – Process flow – Master data Integration with batch management

Unit Objectives After completing this unit, you will be able to: • • • • • •

Name the SAP solutions and components for representing the process chain with in-house production Explain the integration between manufacturing and planning Explain the characteristics of order-controlled production using process orders Describe the cross-application process flow of process manufacturing Name the master data required for process orders Show the logistics process ranging from sales planning to process order creation in a simple application example in the ECC System

Unit Contents Lesson: SAP Solutions and Components for Representing the Process Chain with In-House Production .................................................3 Lesson: Order-Controlled Production using Process Orders .............. 10

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Unit 1: Introduction

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Exercise 1: Exercise 2: Exercise 3: Exercise 4: Exercise 5:

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Order-Controlled Production using Process Orders ...... 23 Sales and Operations Planning ............................. 27 Demand Management ........................................ 31 Material Requirements Planning ............................ 33 Process Order Creation ...................................... 35


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Lesson: SAP Solutions and Components for Representing the Process Chain with In-House Production

Lesson: SAP Solutions and Components for Representing the Process Chain with In-House Production Lesson Overview This lesson familiarizes you with the SAP solutions and components for representing the process chain with in-house production.

Lesson Objectives After completing this lesson, you will be able to: • •

Name the SAP solutions and components for representing the process chain with in-house production Explain the integration between manufacturing and planning

Business Example You first obtain an overview of the current product strategy of SAP. For this purpose, you familiarize yourself with suitable solutions to represent your delivery, procurement and production processes. Of particular interest to you is the integration and realization in the manufacturing area within these solutions.

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mySAP ERP Solution Map (2005)

Figure 1: mySAP ERP Solution Map (2005)

Within the long-term product strategy of SAP, you are provided with a mySAP Business Suite consisting of a number of solutions. The Enterprise Resource Planning (ERP) solution is a comprehensive solution that enables a company to efficiently plan, control and monitor complex delivery, procurement and production networks. This solution supports a synchronized and close interaction between all departments involved (and all people involved) within a logistics chain. Customers, sales, production planning, manufacturing, warehouse management, purchasing, and vendors are all included in this complete solution. The mySAP ERP solution includes a number of areas (see above). You will find further information on the individual components of the mySAP ERP solution at http://www.sap.com/solutions/businessmaps/solutionmaps/ and also here, under Cross-Industry Business Maps.

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mySAP SCM Solution Map (2004)

Figure 2: mySAP SCM Solution Map (2004)

mySAP Supply Chain Management (SCM) is a comprehensive solution that enables an enterprise to efficiently plan, realize and monitor complex delivery, procurement and production relationships (supply chains). This solution supports a synchronized and close interaction between all departments involved (and all people involved) within a logistics chain. Customers, sales, production planning, manufacturing, warehouse management, purchasing, and vendors are all included in this complete solution. In particular, the processing of cross-company processes and the collaborative planning and procurement processes, which also allow for a connection to an open market place, are a main feature of this solution. The mySAP SCM solution includes a number of areas (see above). You will find further information on the individual components of the mySAP SCM solution at http://www.sap.com/solutions/businessmaps/solutionmaps/ and also here, under Cross-Industry Business Maps.

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SAP Components

Figure 3: SAP Components

Various SAP components are used to technically realize the individual solutions. The in-house production is mainly supported by the SAP component SAP ECC. Production planning can be performed with the components SAP ECC and SAP SCM. SAP SCM provides considerably enhanced planning tools (Advanced Planner and Optimizer (APO)), an enhanced Inventory Management function (Inventory Collaboration Hub (ICH)) and Event Management (EM). SAP BW (Business Information Warehouse) is used for separate data retention for variable evaluations. Interfaces for realizing the integration of ECC with SCM, BW or CRM are provided with an appropriate plug-in. The interface between ECC and SCM(APO) is called the Core Interface (CIF). Sales orders can be managed using the component SAP CRM, but also in SAP ECC.

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Integration between Manufacturing and Planning

Figure 4: Integration between Manufacturing and Planning

Production control represents the central part of a complex process chain ranging from an independent requirement (planned or customer requirements) through to the goods issue of finished products.

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Planning: Overview

Figure 5: Planning: Overview

Planning covers several steps that are executed using various components provided in ECC and/or SCM(APO). It is possible, and makes sense, to use both systems together for planning. The systems are integrated via the CIF interface (CIF: Core Interface). Demand planning uses past sales quantities to calculate the future demand program (determination of planned independent requirements). Flexible planning (ECC), standard SOP (ECC) or demand planning (SCM(APO-DP)) can all be used to perform this. Supply Network Planning (SCM(APO)) allows for cross-plant planning of all procurement operations. Sales orders are usually entered in the ECC System. The ATP check of a sales order can take place globally in SCM(APO). Material requirements planning can be performed in both systems. In ECC, capacity requirements planning is executed separately in a second step, while quantities and capacities are planned simultaneously in SCM(APO PP/DS). Production is performed on the basis of planned orders. Here, SAP supports different production types.

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Lesson Summary You should now be able to: • Name the SAP solutions and components for representing the process chain with in-house production • Explain the integration between manufacturing and planning

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Lesson: Order-Controlled Production using Process Orders Lesson Overview This lesson provides you with an overview of the characteristics of order-controlled production using process orders.

Lesson Objectives After completing this lesson, you will be able to: • • • •

Explain the characteristics of order-controlled production using process orders Describe the cross-application process flow of process manufacturing Name the master data required for process orders Show the logistics process ranging from sales planning to process order creation in a simple application example in the ECC System

Business Example Finally, you inform yourself about: • •

The cross-application process flow of process order manufacturing The master data required for process orders

In a simple application example, you show the logistics process ranging from sales planning to process order creation in the ECC System.

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Lesson: Order-Controlled Production using Process Orders

Manufacturing: Production Types

Figure 6: Manufacturing: Production Types

Depending on the manufacturing process, production infrastructure, product complexity, stability of production, and further criteria, a manufacturing company has various requirements with regard to shop floor control. Correspondingly, various production types are supported.

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Application Areas for Process Orders

Figure 7: Application Areas for Process Orders

Due to their special functions, process orders are typically used in the different areas of the process industries. Process orders can be used for different manufacturing processes that are identified, for example, by the criteria of product complexity and product stability.

Process Order (I) A process order • • •

•

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Describes the request asking production to manufacture a material for a specific date in a specific quantity in a production run. Defines which resources (means of production) are used and which ingredients are required to manufacture the material. Is the main control instrument in production. Is used to describe, update, and monitor all production-relevant factors, both planned and actual. Is usually based on a master recipe.


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Process Order (II)

Figure 8: Process Order (II)

A process order describes which material is to be produced, its quantities and dates, the means of production and production methods to be used, as well as the production costs and cost objects to which the costs are to be assigned. All of this information is specified in the planned data and updated in the form of actual production data.

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Process Order-Controlled Production: Characteristics (1)

Figure 9: Process Order-Controlled Production: Characteristics (1)



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Cross-Application Process Flow

Figure 13: Cross-Application Process Flow

Process order management represents a central part of a complex process chain ranging from an independent requirement (planned or customer requirement) through to the goods receipt of finished products. Process order management controls the in-house production process of products (if required together with process management). Process order execution is, for example, integrated with the functions of capacity requirements planning, costing, and inventory management. In addition, there is integration with the ECC batch management and the ECC quality management, and interfaces with laboratory information systems and process control systems.

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Master Data for Process Orders

Figure 14: Master Data for Process Orders

Master data is data in the SAP System which typically remains unchanged for a long period of time. It contains information that is often used in the same manner for similar objects and business processes. The material master record is the central master record in logistics. In general, SAP defines a material as a substance or commodity that is bought or sold on a commercial basis, or is used, consumed, or created in production. A batch is a unique subset of a material. The batches of one material are managed separately in stock. With regard to the production process, a batch is a quantity of a specific material produced during a given production run. This quantity, therefore, represents a unit with unique specifications. The master data for resources describes the means of production in the production process. A production version determines which alternative BOM is used in combination with which master recipe for process order manufacturing. The master data of master recipes describes the manufacture of one or more materials in one production run without relating to a particular order. Material BOMs describe the structure of products that are produced in a company. They are usually created and maintained from the master recipe (integrated maintenance).

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Material and Batch

Figure 15: Material and Batch

In the SAP System, batch master records always depend on their corresponding material master records. Batches are created for a material. In general, the data of a material master record is valid for all batches assigned to it. In contrast, a batch master record contains data that uniquely identifies a batch and characterizes it as a non-reproducible unit. The characteristic batch specifications are assigned using characteristics from the classification system in the material master and are inherited by the corresponding batch master records. If a material is to be produced and managed in batches, the Batch Management Requirement indicator must be set in the material master record. A batch master record is usually created by the system in the background for certain business transactions (such as goods receipt). Users can also create batch master records directly in master data maintenance.

Batch Management Batch management: • •

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Is integrated into all the applications of the ECC System Supports the management and processing of batches in all the business processes of a company


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Features: • • • • • • • • •

Batch number assignment Batch specification (using classification system) Batch determination Active ingredient management (batch-specific units of measure) Batch derivation Batch record Batch where-used list Batch status management Batch Information Cockpit

The batch management is a function for all industry sectors. It is particularly important for the following industry sectors: • • • • • •

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Chemical industry Pharmaceuticals Food industry Cosmetics industry Health and hygiene industry Retail industry


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Batch Management in Supply Chain Management

Figure 16: Batch Management in Supply Chain Management

Batch management is used in all areas of logistics. A batch can be traced across the whole supply chain, from the receipt of the raw materials to processing in production and the creation of the final product, all the way through to sales and delivery to the customer. A batch master record can be used to assign a batch to a material at different places along the supply chain. For example, if the partial quantity of a material produced in batches leaves a production process (process order) with certain specifications, it is posted to stock with a batch number and can be uniquely identified there. If a batch with certain specifications is required in the supply chain, the batch determination function can be used to find suitable batches in stock. In production, batch determination is, for example, used in process orders to find and withdraw suitable material components for the product to be produced.

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Introduction: Topic Summary • • • • •

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Production is a central part of a complex process chain starting with a production requirement and ending with the goods issue of finished products. Various production types are available within the SAP solutions. Using process orders is an order-oriented production control option. Process orders have specific characteristics which determine how they are used in the different areas of process manufacturing industries. An important characteristic is the option to process orders using process management, which is realized with the use of PI sheets and links to process control systems (PI-PCS interface). A further essential characteristic is the use of functions for GMP-compliant production.


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Exercise 1: Order-Controlled Production using Process Orders Exercise Objectives After completing this exercise, you will be able to: • Define a process order • Name the characteristics of process order-controlled production • Explain the cross-application process flow of process manufacturing

Business Example You will get an overview of order-controlled production using process orders.

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Task:

1.

How can a process order be defined? Refer to the “Process Order (I), (II)” pages in your participant handbook to answer the question.

2.

Get an overview of the characteristics of process order-controlled production. Refer to the information on the pages “Process Order-Controlled Production: Characteristics (1) – (4)” in your participant handbook.

3.

Describe the cross-application process of process manufacturing. Refer to the information on the page “Cross-Application Process Flow” in your participant handbook.

4.

Get an overview of the ECC menu structure with regard to the functions of production planning and control for process industries. Try to assign the terms Master data maintenance, Production planning, and Shop floor control to the main menu entries.

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Solution 1: Order-Controlled Production using Process Orders Task: 1.

How can a process order be defined? Refer to the “Process Order (I), (II)” pages in your participant handbook to answer the question. Answer: See exercise

2.

Get an overview of the characteristics of process order-controlled production. Refer to the information on the pages “Process Order-Controlled Production: Characteristics (1) – (4)” in your participant handbook. Answer: See exercise

3.

Describe the cross-application process of process manufacturing. Refer to the information on the page “Cross-Application Process Flow” in your participant handbook. Answer: See exercise

4.

Get an overview of the ECC menu structure with regard to the functions of production planning and control for process industries. Try to assign the terms Master data maintenance, Production planning, and Shop floor control to the main menu entries. a)

SAP Menu → Logistics → Production-Process → (...) The menus appear for • • • •

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Master data maintenance Production planning (sales and operation planning, production planning, MRP) Shop floor control (process order, production campaign, process planning, process management) Product cost planning


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Exercise 2: Sales and Operations Planning Exercise Objectives After completing this exercise, you will be able to: • Display a product group • Create a sales plan and a production plan • Perform disaggregation of product group quantities and a transfer to demand management

Business Example Note: In this exercise and the following exercises, you will carry out a simple example illustrating the cross-application process of process manufacturing from sales planning through to process order creation in the ECC System. Refer to the page “SC Planning: Overview” in your participant handbook to get an overview of alternative planning scenarios. In this scenario, we assume that the basis for a demand program to be created (determination of planned independent requirements) is Sales and Operations Planning in the ECC System. If the relevant system settings were made, we could also use Flexible Planning in the ECC System or Demand Planning in SAP(APO) as an alternative. You will display the product group T-ICE## Ice cream products. You will first create a sales plan for this product group and then a production plan based on this sales plan. You will then disaggregate the planned product group quantities of your production plan to the individual product group members and transfer the results to demand management (to determine the planned independent requirements).

Task: 1.

Display product group T-ICE## in plant 1100. Which product group members does the product group have? Which disaggregation proportions (in %) have been defined for the individual product group members?

Continued on next page

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Member number

2.

Plant

Proportion (%)

Create a sales plan for your product group T-ICE## in plant 1100. Choose Active version. Starting from the month after next, the planned sales quantities should be 10,000 kg per month for five consecutive months. Note: The active version already exists. For this reason, start planning in the change mode.

3.

Based on your sales plan, create a production plan for your product group T-ICE##. Choose Active version. Start planning in the change mode. Specify that the production plan is to be created synchronous to the sales plan.

4.

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Disaggregate the planned product group quantities of your production plan to the individual product group members and transfer the results to demand management.


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Solution 2: Sales and Operations Planning Task: 1.

Display product group T-ICE## in plant 1100. Which product group members does the product group have? Which disaggregation proportions (in %) have been defined for the individual product group members? Member number

a)

Plant

Proportion (%)

Logistics → Production - Process → SOP → Product Group → Display Product group:

T-ICE##

Plant:

1100

Choose Enter. The Display Product Group: Members (Materials) screen appears.

2.

Number

Member (Plant)

Proportion (%)

T-FI1##

1100

60

T-FI2##

1100

30

T-FI3##

1100

10

Create a sales plan for your product group T-ICE## in plant 1100. Choose Active version.


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Starting from the month after next, the planned sales quantities should be 10,000 kg per month for five consecutive months. Note: The active version already exists. For this reason, start planning in the change mode. a)

Logistics → Production - Process → SOP → Planning → For Product Group → Change Product group:

T-ICE##

Plant:

1100

Choose Active version. The Change Sales and Operation Planning screen appears. Enter the sales quantities of 10,000 kg per month for five consecutive months, starting from the month after next. Save your sales plan. 3.

Based on your sales plan, create a production plan for your product group T-ICE##. Choose Active version. Start planning in the change mode. Specify that the production plan is to be created synchronous to the sales plan. a)

(...) → SOP → Planning → For Product Group → Change Choose Active version. Choose Edit → Create product. plan → Synchronous to sales Save your planning results.

4.

Disaggregate the planned product group quantities of your production plan to the individual product group members and transfer the results to demand management. a)

(…) → SOP → Disaggregation → Transfer Product Group to Planning Product group:

T-ICE##

Plant:

1100

Version:

A00

Choose the transfer strategy Prod.plan for mat. or PG members as proportion of PG. Choose Transfer now.

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Exercise 3: Demand Management Exercise Objectives After completing this exercise, you will be able to: • Display planned independent requirements • Display current stock / requirements lists

Business Example You will display the planned independent requirements for your product group T-ICE##. You will also display the current stock/requirements list for materials T-FI1##, T-FI2##, and T-FI3##.

Task: 1.

Display the planned independent requirements for your product group T-ICE##. Compare the planned independent requirement quantities for materials T-FI1##, T-FI2##, and T-FI3## in the planning table with the planned values in the production plan and the percentage disaggregation proportions in the product group.

2.

Display the current stock/requirements lists for materials T-FI1##, T-FI2##, and T-FI3##. What information do the stock/requirements lists provide?

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Solution 3: Demand Management Task: 1.

Display the planned independent requirements for your product group T-ICE##. Compare the planned independent requirement quantities for materials T-FI1##, T-FI2##, and T-FI3## in the planning table with the planned values in the production plan and the percentage disaggregation proportions in the product group. a)

Logistics → Production - Process → Production Planning → Demand Management → Planned Independent Requirement → Display Product group

T-ICE##

Plant:

1100

Choose Enter. The Plnd Ind. Reqmts Display: Planning Table screen appears. 2.

Display the current stock/requirements lists for materials T-FI1##, T-FI2##, and T-FI3##. What information do the stock/requirements lists provide? a)

(…) → Demand management → Environment → Stock/reqmts list Material: T-FI1## or T-FI2## or T-FI3## Plant: 1100 At this stage, the list contains the planned independent requirements for materials T-FI1##, T-FI2##, and T-FI3## together with the requirement quantities and requirement dates. It also provides information on the quantities that are available today and on the requirements dates.

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Exercise 4: Material Requirements Planning Exercise Objectives After completing this exercise, you will be able to: • Perform a planning run • Evaluate the planning result

Business Example You will run material requirements planning for your material T-FI1##. You display the planning results in the form of planned orders in the stock/requirements list. Note: If the system settings were made accordingly, the planning run could also be carried out in SCM(APO) and the planned orders resulting from it could be transferred to the ECC System.

Task: 1.

Carry out multilevel single-item planning for your material T-FI1## in plant 1100.

2.

Display the stock/requirements list for material T-FI1## after the planning run. Which MRP data has been changed? Which MRP elements are new?

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Solution 4: Material Requirements Planning Task: 1.

Carry out multilevel single-item planning for your material T-FI1## in plant 1100. a)

Logistics → Production - Process → MRP → Planning → Single-Item, Multi-Level Material:

T-FI1##

Plant:

1100

Choose Enter. The system displays an info message prompting you to check the input parameters. Choose Enter again to start the MRP run. 2.

Display the stock/requirements list for material T-FI1## after the planning run. Which MRP data has been changed? Which MRP elements are new? a)

(…) → MRP → Evaluations → Stock/Requirements List Material: T-FI1## Plant: 1100 As a result of the MRP run, the system created planned orders to cover the planned independent requirements.

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Exercise 5: Process Order Creation Exercise Objectives After completing this exercise, you will be able to: • Perform a planned order conversion

Business Example You will convert one of your planned orders to a process order. Note: If planning was carried out in SCM (APO), planned order conversion could also be triggered in SCM (APO). The process order would then be created in the ECC System and mirrored back to SCM (APO). Process order processing (material movements, confirmations, and so on) can only take place in the ECC System.

Task: 1.

Display the stock/requirements list for your product T-FI1##. Convert the planned order for the earliest date to a process order from within this list. Refresh the list after the conversion and describe what has changed.

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Solution 5: Process Order Creation Task: 1.

Display the stock/requirements list for your product T-FI1##. Convert the planned order for the earliest date to a process order from within this list. Refresh the list after the conversion and describe what has changed. a)

Logistics → Production - Process → MRP → Evaluations → Stock/Requirements List Material: T-FI1## Plant: 1100 Double-click the MRP element PLOrd for the first planned order and in the dialog box choose Additional Data for MRP Element → ProcOrd After converting, the Create Process Order: Header - General Data screen appears in the process order: Save the process order. After saving, the stock/requirements list appears again. Choose the Refresh icon. The new process order is displayed as a new MRP element. The order number is displayed in the data on the MRP element. The original planned order was deleted after the conversion.

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Lesson Summary You should now be able to: • Explain the characteristics of order-controlled production using process orders • Describe the cross-application process flow of process manufacturing • Name the master data required for process orders • Show the logistics process ranging from sales planning to process order creation in a simple application example in the ECC System

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Unit Summary

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Unit Summary You should now be able to: • Name the SAP solutions and components for representing the process chain with in-house production • Explain the integration between manufacturing and planning • Explain the characteristics of order-controlled production using process orders • Describe the cross-application process flow of process manufacturing • Name the master data required for process orders • Show the logistics process ranging from sales planning to process order creation in a simple application example in the ECC System

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Test Your Knowledge

Test Your Knowledge

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1.

Which SAP components are available for the realization of production planning?

2.

Name some basic functions of process orders


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Answers 1.

Which SAP components are available for the realization of production planning? Answer: • •

2.

SAP ECC SAP SCM(APO)

Name some basic functions of process orders Answer: • • • • • • • • • • • • • • • • • • • • •

40

Status management Production based on a production version Scheduling Determination of capacity requirements Costing Batch number assignment Manufacture of co-products Availability checks Material quantity calculation Active ingredient management Batch determination Resource network Resource selection Printing of shop floor papers Creation of control recipes for the process control level Material staging through reservations Confirmation of quantities, activities and time events Goods receipt Period-end closing (order settlement, among other things) Archiving and retrieval Bulk processing


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Unit 2 Order Structure and Processing Unit Overview Topics: • • •

Process order structure and elements Process order screens and data Process order processing

Unit Objectives After completing this unit, you will be able to: • • • •

Describe the structure and elements of a process order Navigate in the process order and explain the most important screens and their contents Describe process order processing Carry out order processing up to PI sheet maintenance in the ECC System using a simple scenario

Unit Contents Lesson: Process Order Structure and Elements ............................ 42 Exercise 6: Process Order Structure and Elements .................... 45 Lesson: Process Order Processing ........................................... 56 Exercise 7: Process Order Processing ................................... 59

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Lesson: Process Order Structure and Elements Lesson Overview This lesson informs you about the data structure for a process order.


Describe the structure and elements of a process order Navigate in the process order and explain the most important screens and their contents

Business Example You analyze the data structure of a process order: • •

You will learn how to navigate in the order. You will get an overview of which information can be found on which screens.

Process Order Structure

Figure 17: Process Order Structure

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Lesson: Process Order Structure and Elements

Operations describe the different steps required during the production process. For a more detailed description of these steps, phases are assigned to the operations. Exactly one resource is assigned to an operation. This resource assignment also applies to all phases assigned to the operation. The phases' processing sequence in time is defined in relationships. The material list is made up of components representing the materials entering and leaving the production process, as well as temporarily existing materials and their planned quantities. It also defines the assignment of these material components to the phases of the order according to their appearance in the process. In material quantity calculation, you define formulas to calculate the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the ingredients, yield ratios of the products and remaining materials, as well as specific material attributes (for example, active ingredient). A process order is usually created using a master recipe. The operation and phase structure together with its relationships and assigned resources, as well as material components and process instructions are copied to the process order.

Elements of the Process Order

Figure 18: Elements of the Process Order

Phases are used for scheduling, determining capacity requirements, and costing. The dates and capacity requirements for operations are derived from the corresponding phases.

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If required, further (secondary) resources can be assigned to operations and phases. The same business transactions can be carried out for secondary resources as for phases. Secondary resources can, for example, be included in scheduling, capacity requirements planning, and costing. A control key must be entered for both the phases and the secondary resources. The control key is used to determine how an operation or phase is to be treated in operative applications such as process orders, costing, or capacity requirements planning. A standard value is a planned value used to carry out a phase or secondary resource, such as the execution time. Standard values are used for calculations in costing, scheduling, and capacity requirements planning. Confirmations are entered for phases and secondary resources (however, not for operations). Data for process management: Alternative 1: Process instructions are structures that are used to transfer data from the process order to process control (PI sheet or process control system). Process instructions are assigned to the phases of a process order. The process instructions are combined into control recipes, which are then transferred to the control recipe destinations defined for the phases. Data for process management: Alternative 2: From SAP R/3 ERP and SCM Extension 2.00 (EA_APPL_2.00), the data for the process management can alternatively be maintained in the form of XSteps (execution steps). Using XSteps enables you to maintain process instructions in the form of reusable and referenceable modules. A Standard XStep Repository with version management is available.

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Exercise 6: Process Order Structure and Elements Exercise Objectives After completing this exercise, you will be able to: • Navigate in process orders

Business Example You will analyze the data structure for the process order you created for material T-FI1## . • •

You will learn how to navigate in the order. You will get an overview of which information can be found on which screens.

Task 1: 1.

Display the stock/requirements list for your product T-FI1##. Call up your process order in the change mode.

Task 2: Analyze the structure and elements of your process order. Hint: The following exercises are only meant to give you an idea of how you can become familiar with the process order. They do not claim to be complete as far as the screens and data to be displayed are concerned. Instead, they will give you an overview of the type of information stored in orders and on which views, screens, and so on, it can be found. If required, refer to the information on the pages “Process Order Structure” and “Elements of the Process Order” in your participant handbook. In addition, use Application help and, for more detailed information, F1 and F4 help if required. 1.

First, get an overview of the navigation between the Header, Operations (Operation Overview) and Materials (Material List) views.

2.

Navigate to the order header. Write down the following: Continued on next page

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Order number: __________________________ (Order) type: __________________________ (Double-click to navigate to the order type-dependent parameters) Material: __________________________ (You can navigate to the material master record.) Plant: __________________________ Status: __________________________ 3.

Get an overview of the different order header screens. Header - General Data Note the quantities and dates fields. Header-Assignments Write down the following: MRP controller: __________________________ Production scheduler: _________________________ Planning plant: __________________________ Planned order: __________________________ Note that a sales order (from SD) and an inspection lot (from Quality Management) could be assigned. Header – Goods Receipt Write down the following: Stock type: __________________________ Storage location: __________________________ Note that a batch number can be assigned for product T-FI1##. Note that delivery tolerances can be defined. Header – Control Data Write down the following: Reservation/Purc.req.: __________________________ Plan cost calculation: __________________________ Capacity reqmts: __________________________ Schedule automat.: __________________________ Header - Dates/Quantities Continued on next page

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Note the quantities and dates fields for the planned order and process order. Header – Master Data Write down the following: Production version: __________________________ Recipe group/Recipe: __________________________ BOM/Alternative: __________________________ Resource network: __________________________ You can navigate to the master recipe, the BOM, and the resource network from this view. Header – Administrative Data Write down the following: Created/User: __________________________ Navigate to Settlement rule (Header → Settlement rule) Which settlement receiver should the costs for this order be settled on? (Account assignment) category: __________________________ Settlement receiver: __________________________ Receiver short text: __________________________ 4.

Navigate to the Operation overview for the order. Get an overview of the operations, phases, and resources assigned to the order. Compare the entries with the corresponding data in the master recipe. Note that a control recipe destination is defined per phase. Note that you can use the corresponding icons (or by choosing the menu path Operation →) to navigate per phase to the lists - Material assignments, - Relationships, - Secondary resources and - Process instructions

5.

Get an overview of the detailed data for a phase. Continued on next page

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General Data Write down the following: Resource: __________________________ (You can navigate to the resource.) Control key: __________________________ Status: __________________________ Confirmation number __________________________ Cost: __________________________ Standard Values Write down the following: Operation quantity: __________________________ Standard value: __________________________ Activity type: __________________________ Dates Note the fields for scheduled and confirmed phase dates. Note the planned phase processing time. Qty/activities Note the fields for the quantities and activities to be confirmed and already confirmed. 6.

Navigate to the Material list for the order. Get an overview of the material components that have been assigned. Compare the entries with the corresponding data in the master recipe. Note the Phase assignment of the components. Note that the Batch field for components to be handled in batches is ready for input and the Batch determination function is available for determining a suitable batch. Note that the Material quantity calculation function is available for a detailed definition of the quantity proportions.

7.

Get an overview of the detail data for a material component. Write down the following: Material: __________________________ (You can navigate to the material master record.) Continued on next page

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Storage location: __________________________ __________________________ (if defined) Batch: __________________________ __________________________ (if defined) (The Batch field is ready for input for components to be handled in batches.) Status: __________________________ Reservation: __________________________ Movement type: __________________________ In addition, note the data on quantities and dates as well as the General indicators for the material component. 8.

Get an overview (by choosing Goto → ...) of the - Logs - Lists - Costs for the order.

9.

Get an overview (by choosing Process order → Functions ...) of the functions for the order.

10. Get an overview (by choosing Operation → Functions for phase / for operation → ...) of the functions for the phases or operations.

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Solution 6: Process Order Structure and Elements Task 1: 1.

Display the stock/requirements list for your product T-FI1##. Call up your process order in the change mode. a)

Logistics → Production Process → Process Order → Environment → Stock/Requirements List Material:

T-FI1##

Plant:

1100

Double-click the MRP element PrcOrd. On the Additional Data for MRP Element dialog box, choose the Change element (F8) icon.

Task 2: Analyze the structure and elements of your process order. Hint: The following exercises are only meant to give you an idea of how you can become familiar with the process order. They do not claim to be complete as far as the screens and data to be displayed are concerned. Instead, they will give you an overview of the type of information stored in orders and on which views, screens, and so on, it can be found. If required, refer to the information on the pages “Process Order Structure” and “Elements of the Process Order” in your participant handbook. In addition, use Application help and, for more detailed information, F1 and F4 help if required. 1.

First, get an overview of the navigation between the Header, Operations (Operation Overview) and Materials (Material List) views. a)

2.

Choose the Header icon and the Operations and Materials buttons to navigate in the process order.

Navigate to the order header. Write down the following: Order number: __________________________ Continued on next page

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(Order) type: __________________________ (Double-click to navigate to the order type-dependent parameters) Material: __________________________ (You can navigate to the material master record.) Plant: __________________________ Status: __________________________ a) 3.

Choose the Header icon.

Get an overview of the different order header screens. Header - General Data Note the quantities and dates fields. Header-Assignments Write down the following: MRP controller: __________________________ Production scheduler: _________________________ Planning plant: __________________________ Planned order: __________________________ Note that a sales order (from SD) and an inspection lot (from Quality Management) could be assigned. Header – Goods Receipt Write down the following: Stock type: __________________________ Storage location: __________________________ Note that a batch number can be assigned for product T-FI1##. Note that delivery tolerances can be defined. Header – Control Data Write down the following: Reservation/Purc.req.: __________________________ Plan cost calculation: __________________________ Capacity reqmts: __________________________ Schedule automat.: __________________________ Header - Dates/Quantities Continued on next page

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Note the quantities and dates fields for the planned order and process order. Header – Master Data Write down the following: Production version: __________________________ Recipe group/Recipe: __________________________ BOM/Alternative: __________________________ Resource network: __________________________ You can navigate to the master recipe, the BOM, and the resource network from this view. Header – Administrative Data Write down the following: Created/User: __________________________ Navigate to Settlement rule (Header → Settlement rule) Which settlement receiver should the costs for this order be settled on? (Account assignment) category: __________________________ Settlement receiver: __________________________ Receiver short text: __________________________ a)

Choose the corresponding tab to navigate to the order header. Choose Header → Settlement rule to navigate to the settlement rule.

4.

Navigate to the Operation overview for the order. Get an overview of the operations, phases, and resources assigned to the order. Compare the entries with the corresponding data in the master recipe. Note that a control recipe destination is defined per phase. Note that you can use the corresponding icons (or by choosing the menu path Operation →) to navigate per phase to the lists - Material assignments, - Relationships, - Secondary resources and - Process instructions Continued on next page

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a) 5.

Choose Operations.

Get an overview of the detailed data for a phase. General Data Write down the following: Resource: __________________________ (You can navigate to the resource.) Control key: __________________________ Status: __________________________ Confirmation number __________________________ Cost: __________________________ Standard Values Write down the following: Operation quantity: __________________________ Standard value: __________________________ Activity type: __________________________ Dates Note the fields for scheduled and confirmed phase dates. Note the planned phase processing time. Qty/activities Note the fields for the quantities and activities to be confirmed and already confirmed. a)

Double-click the phase number to navigate to the phase detail screens. Choose the corresponding tabs to navigate further.

6.

Navigate to the Material list for the order. Get an overview of the material components that have been assigned. Compare the entries with the corresponding data in the master recipe. Note the Phase assignment of the components. Note that the Batch field for components to be handled in batches is ready for input and the Batch determination function is available for determining a suitable batch. Continued on next page

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Note that the Material quantity calculation function is available for a detailed definition of the quantity proportions. a) 7.

Choose Materials.

Get an overview of the detail data for a material component. Write down the following: Material: __________________________ (You can navigate to the material master record.) Storage location: __________________________ __________________________ (if defined) Batch: __________________________ __________________________ (if defined) (The Batch field is ready for input for components to be handled in batches.) Status: __________________________ Reservation: __________________________ Movement type: __________________________ In addition, note the data on quantities and dates as well as the General indicators for the material component. a)

8.

Double-click the item number to navigate to the component detail screens.

Get an overview (by choosing Goto → ...) of the - Logs - Lists - Costs for the order. a)

9.

Choose Goto → ...

Get an overview (by choosing Process order → Functions ...) of the functions for the order. a)

Process order → Function → ...

10. Get an overview (by choosing Operation → Functions for phase / for operation → ...) of the functions for the phases or operations. a)

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Lesson Summary You should now be able to: • Describe the structure and elements of a process order • Navigate in the process order and explain the most important screens and their contents

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Lesson: Process Order Processing Lesson Overview This lesson informs you about process order processing.


Describe process order processing Carry out order processing up to PI sheet maintenance in the ECC System using a simple scenario

Business Example You release the order, and create and send the corresponding control recipe. Finally, you display the PI sheet for the order.

Process Order Processing

Figure 19: Process Order Processing

The graphic shows the main steps that are carried out during process order management to control process manufacturing in the SAP system.

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Lesson: Process Order Processing

Process order processing can be divided into the following steps: • • •

Process planning Process order execution/process management Order closing

Many of these activities can run automatically or in the background so that manual processing of orders is minimized. WIP determination, deviation determination, and settlement are generally periodic work for Cost Object Controlling and are usually processed in the background. A number of settings must be made (Customizing) for each step to allow for successful order processing.

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Exercise 7: Process Order Processing Exercise Objectives After completing this exercise, you will be able to: • Describe process order processing • Perform a process order release • Create and send control recipes • Display the PI sheet

Business Example You will first get an overview of the main steps that are carried out in the course of process order management. You will then release your process order and create the control recipe for the order. You will send the control recipe and display the PI sheet that is created when you send the control recipe.

Task 1: 1.

Get an overview of process order processing. Refer to the information on the page “Process Order Processing” in your participant handbook.

Task 2: Call up your process order in the change mode. 1.

Call up your process order in the change mode.

2.

On the Header – Goods Receipt screen, manually assign the following number for the batch of material T-FI1## to be produced: Batch: SCM340

3.

On the Material list screen, manually carry out batch determination for one or more material components.

4.

Manually perform a material availability check for the order.

5.

Manually perform a capacity availability check for the order.

6.

Release the process order. Create the control recipe for the order. Continued on next page

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Save the order.

Task 3: 1.

Select your control recipe in the control recipe monitor. Send the control recipe and refresh the list display. Hint: In the production plant, control recipes are sent automatically in a job.

Task 4: 1.

Your control recipe destination is of the type PI sheet. Select the PI sheet created when the control recipe was sent. Enter the PI sheet in the display mode. Hint: You will not process the process order any further in this unit.

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Solution 7: Process Order Processing Task 1: 1.

Get an overview of process order processing. Refer to the information on the page “Process Order Processing” in your participant handbook. a)

See exercise

Task 2: Call up your process order in the change mode. 1.

Call up your process order in the change mode. a)

Call up the stock / requirements list or Logistics → Production-Process → Process Order → Process Order → Change

2.

On the Header – Goods Receipt screen, manually assign the following number for the batch of material T-FI1## to be produced: Batch: SCM340 a)

3.

See exercise

On the Material list screen, manually carry out batch determination for one or more material components. a)

Manual batch determination: Select a material component and choose the Execute batch determntn icon in the lower toolbar. Hint: For component T-RI2##, batch determination is carried out in the dialog mode. All other components to be handled in batches are assigned in the background.

4.

Manually perform a material availability check for the order. a)

5.

Choose Material (Material availability check - ATP) in the application toolbar.

Manually perform a capacity availability check for the order. a)

Choose Capacity (Capacity availability check) in the application toolbar. Continued on next page

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Release the process order. Create the control recipe for the order. Save the order. a)

Release: Choose the Release icon in the application toolbar. Control recipe creation: Choose the Create control recipe icon in the application toolbar.

Task 3: 1.

Select your control recipe in the control recipe monitor. Send the control recipe and refresh the list display. Hint: In the production plant, control recipes are sent automatically in a job. a)

Logistics → Production-Process → Process Management → Control Recipe → Control Recipe Monitor Plant

1100

Process order:

Process order number

or Destination address:

GRP. ## ICE

Choose Enter. The Control Recipe Monitor: Overview screen appears. The control recipe status is Created. Select your control recipe and choose Send. After sending, choose Refresh to update the list. The control recipe must now have status Sent.

Task 4: 1.

Your control recipe destination is of the type PI sheet. Select the PI sheet created when the control recipe was sent.


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Enter the PI sheet in the display mode. Hint: You will not process the process order any further in this unit. a)

Select your PI sheet using (…) → Process Management → PI Sheet → Find or (…) → Process Management → PI Sheet → Worklist - Maintain Choose appropriate selection criteria.

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Lesson Summary You should now be able to: • Describe process order processing • Carry out order processing up to PI sheet maintenance in the ECC System using a simple scenario

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Unit Summary

Unit Summary You should now be able to: • Describe the structure and elements of a process order • Navigate in the process order and explain the most important screens and their contents • Describe process order processing • Carry out order processing up to PI sheet maintenance in the ECC System using a simple scenario

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Test Your Knowledge

Test Your Knowledge

2005/Q2

1.

Describe the basic structure of a process order.

2.

Describe the basic steps of process order processing.


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Answers 1.

Describe the basic structure of a process order. Answer: •

Order header –

•

Operation overview –

•

with operation, phase and resource information

Material list –

68

with material, quantities, dates and status information

with information on the material components


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Test Your Knowledge

2.

Describe the basic steps of process order processing. Answer: •

Process planning

•

– Order creation – Resource/line reservation – Resource selection – Batch number assignment (product) – Batch determination (components) – Material quantity calculation Process order execution

•

– Order release – Shop paper printing – Control recipe sending – PI sheet maintenance – Sending process messages – Material staging/material withdrawal – Confirmations – In-process – quality inspections – Goods receipts Order closing – – – –

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Variance calculation Order settlement Batch record Archiving and deleting


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Unit 3 Order Creation

Unit Overview Topics: • • • • • •

Options for creating process orders Activities in the process order creation Order type Production version selection Scheduling Planned costs

Unit Objectives After completing this unit, you will be able to: • • • • • • • • • • •

• •

2005/Q2

Use the different options for creating a process order Explain the activities involved in process order creation Define order types and order type-dependent parameters in Customizing Make the appropriate Customizing settings for master data selection Make the appropriate material master settings for selection using a production version Explain the selection using a production version in manual process order creation and planned order conversion Use the production version selection based on a quota arrangement Select production versions manually Read production versions Include master recipes Perform the following Customizing activities for scheduling process orders: define scheduling types, set scheduling parameters, define scheduling margins Trace the scheduling of process orders in detail Determine the planned costs for a process order.


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Unit Contents Lesson: Order Creation ......................................................... 73 Exercise 8: Order Creation................................................. 77 Lesson: Master Data Selection ................................................ 90 Exercise 9: Order Type ....................................................103 Exercise 10: Master Data Selection .....................................107 Exercise 11: Production Version Selection Based on a Quota Arrangement ................................................................123 Exercise 12: Manual Production Version Selection ....................139 Lesson: Scheduling.............................................................144 Exercise 13: Scheduling...................................................147 Lesson: Costing .................................................................163 Exercise 14: Costing .......................................................165 Exercise 15: Mass Processing............................................167

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Lesson: Order Creation

Lesson: Order Creation Lesson Overview This lesson informs you about the different options for creating a process order.


Use the different options for creating a process order Explain the activities involved in process order creation

Business Example You test the different ways of creating a process order. You get an overview of the system activities involved during order creation.

Process Planning: Order Creation

Figure 20: Process Planning: Order Creation

The graphic illustrates the main activities and functions of process planning.

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A process order can be created manually or by converting a planned order. The production quantity and planned order dates are either copied from the planned order or entered manually. A production version with a master recipe is selected as the basis for the process order. It provides a detailed description of the planned manufacturing process. During order creation, the process order is scheduled, the required capacity requirements are determined, and the planned costs are calculated. Data and formulas from the master recipe and the assigned resources are used as a basis for these activities. In capacity requirements planning, the capacity requirements of order operations are dispatched at the corresponding resources (resource reservation). During the material availability check, different criteria can be used to check whether the material components needed for the order are available. Batch determination can be used for the system-aided assignment of batches required for production.

Alternative Ways of Creating a Process Order

Figure 21: Alternative Ways of Creating a Process Order

The graphic illustrates the different ways of creating process orders. In the course of integrated production planning and control, process orders are usually created by converting planned orders created in material requirements planning. In addition, you can always create a process order manually. When converting planned orders into process orders, the material to be produced as well as the order quantity, basic dates, and production version are automatically copied to the process order. The production scheduler can choose the planned orders to be converted from a material-specific time window (opening period).

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During process order creation, a master recipe is usually selected through a production version and used as the basis for the process order. There are situations when you may want to create a process order without using a production version and/or master recipe. In Customizing, you can specify whether a master recipe must be selected for a process order and define the selection criteria to be used. You can also create a process order without reference to a material, for example, to test an automated plant line. When you create a process order manually, you can use an existing order as a template to copy from.

Special Creation Variants

Figure 22: Special Creation Variants

The graphic illustrates further order creation variants that are used in special cases.

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Activities Involved in Process Order Creation

Figure 23: Activities Involved in Process Order Creation

The graphic shows the main functions that are carried out when you create a process order. By making the corresponding Customizing settings, you can control how these activities are performed. All these functions are usually carried out in the background (except for order type specification and manual quantity and dates entry in scenario (2)). The production scheduler does not have to do anything unless a problem occurs (for example, if a master recipe does not exist). Other functions that can run automatically if the relevant Customizing settings have been made, are, for example: Material availability, batch creation for the product, order classification, order release

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Exercise 8: Order Creation Exercise Objectives After completing this exercise, you will be able to: • Perform the individual conversion of a planned order • Perform the partial conversion of a planned order • Perform the collective conversion of planned orders • Create a process order with reference to a material • Create a process order with a template • Create a process order without reference to a material

Business Example You will get an overview of the different ways to create a process order.

Task 1: 1.

Display the stock/requirements list for your material T-FI1##. Write down the order number of the planned order that comes next in time. ____________________________________________________________

Task 2: 1.

Convert the planned order of exercise 1-1 to a process order. Use individual conversion. Choose process order type PI01 for conversion.

Task 3: Display the stock/requirements list for material T-FI1##. 1.

Display the stock/requirements list for material T-FI1##.


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2.

Which changes have occurred?

3.

Write down the order number of the planned order that comes next in time.

Task 4: 1.

Convert the planned order from exercise 3-3 to a process order. Use partial conversion. Use process order type PI01 for partial conversion. Convert half of the planned quantity.


Display the stock/requirements list for material T-FI1##.

2.

Which changes have occurred?

3.

There are two more planned orders in the list. Display the two orders. Write down the order number, the planned opening date, and the assigned MRP controller for each of these planned orders.


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Planned order

Creation date

MRP controller

Task 6: 1.

Convert the two planned orders from exercise 5-3 to process orders. Use collective conversion. Enter the following criteria for planned order selection: Plant:

1100

MRP controller:

I##

Creation:

Creation date of the planned order that is chronologically first Creation date of the planned order that is chronologically last

Choose process order type PI01 for conversion.


Display the stock/requirements list for material T-FI1##. Which changes have occurred? ____________________________________________________________ ____________________________________________________________

Task 8: 1.

Create another process order with reference to your material T-FI1##. Choose process order type PI01 and production plant 1100. Enter 14,000 pieces as the total quantity you want to produce and today as the basic start date. Save the order and write down the order number. ____________________________________________________________ Continued on next page

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Task 9: 1.

Create another process order of order type PI01 in plant 1100. This time, use the order created in 8-1 as a template to copy from. Enter 16,000 pieces as the total quantity you want to produce and Today + 1 week as the basic start date.

Task 10: 1.

Now create a process order of process order type PI01 in plant 1100 without reference to a material. Create the order with reference to recipe 1 Clean-out of recipe group T-CLEAN. Enter 1 PU (activity unit) as the total quantity and any start date you wish. In the distribution rules of the settlement rule, define cost center 4271 Production food as the settlement receiver for the clean-out order.

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Solution 8: Order Creation Task 1: 1.

Display the stock/requirements list for your material T-FI1##. Write down the order number of the planned order that comes next in time. ____________________________________________________________ a)

Logistics → Production - Process → MRP → Evaluations → Stock/Requirements List Material:

T-FI1##

Plant:

1100

The planned order number is displayed in the data on the MRP element.

Task 2: 1.

Convert the planned order of exercise 1-1 to a process order. Use individual conversion. Choose process order type PI01 for conversion. a)

(…) → MRP → Planned Order → Convert to Proc.Ord. → Individual Conversion Planned order:

Planned order number

Process order type:

PI01

Choose Enter. The system converts the planned order to a process order. The Create Process Order: Header - General Data screen then appears. Save the process order.


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Display the stock/requirements list for material T-FI1##. a)

2.


T-FI1##

Plant:

1100

Which changes have occurred? Answer: The new process order is displayed as a new MRP element. The planned order was deleted after conversion.

3.

Write down the order number of the planned order that comes next in time. Answer: The planned order number is displayed in the data on the MRP element.

Task 4: 1.

Convert the planned order from exercise 3-3 to a process order. Use partial conversion. Use process order type PI01 for partial conversion.


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Convert half of the planned quantity. a)

(…) → MRP → Planned Order → Convert to Proc.Ord. → Partial Conversion Planned order:


Process order type:

PI01

The Partial conversion indicator is set. Choose Enter. The Plnd Ind. Reqmts Create: Initial screen appears. The system proposes a target quantity of 6,000 kg. Change the quantity to 3,000 kg and save your order. The following information message appears: Orders will be generated for partial quantities before saving. Choose Enter to confirm the message. The planned order is partially converted to a process order. Choose Back to exit the Create Process Order: Initial screen.


Display the stock/requirements list for material T-FI1##. a)

2.


T-FI1##

Plant:

1100

Which changes have occurred? Answer: Due to the partial conversion, the system created a process order with a corresponding order quantity. The planned order is still available. The planned order quantity has been reduced by the converted quantity. The planned order was firmed.

3.

There are two more planned orders in the list. Display the two orders. Write down the order number, the planned opening date, and the assigned MRP controller for each of these planned orders. Continued on next page

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Planned order

a)

Creation date

MRP controller

Position the cursor on the MRP element of a planned order and choose the Display element icon in the toolbar at the bottom of the screen.

Task 6: 1.

Convert the two planned orders from exercise 5-3 to process orders. Use collective conversion. Enter the following criteria for planned order selection: Plant:

1100

MRP controller:

I##

Creation:

Creation date of the planned order that is chronologically first Creation date of the planned order that is chronologically last


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Choose process order type PI01 for conversion. a)

(…) → MRP → Planned Order → Convert to Proc.Ord. → Collective Conversion Plant:

1100

MRP controller:

I##

Creation:

Creation date of the planned order that is chronologically first - Creation date of the planned order that is chronologically last

Process order type:

PI01

Choose the Execute selections icon. The Collective Conversion of Planned Orders: List screen appears. According to the selection criteria you have entered, the system only displays your two planned orders for material T-FI1##. Select the two planned orders and choose Convert. The planned orders are now converted to process orders one after the other. Choose Back to exit the list.


Display the stock/requirements list for material T-FI1##. Which changes have occurred? ____________________________________________________________ ____________________________________________________________ a)


T-FI1##

Plant:

1100

The two new process orders are displayed as new MRP elements. The planned orders were deleted after the conversion.


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Task 8: 1.

Create another process order with reference to your material T-FI1##. Choose process order type PI01 and production plant 1100. Enter 14,000 pieces as the total quantity you want to produce and today as the basic start date. Save the order and write down the order number. ____________________________________________________________ a)

Logistics → Production Process → Process Order → Process Order → Create → With Material Material number:

T-FI1##

Production plant:

1100

Process order type:

PI01

Choose Enter. The Create Process Order: Header – General Data screen appears. Total quantity:

14,000 PC

Start:

Today

Choose Enter. The system creates the process order. Save the order and write down the order number: ____________________

Task 9: 1.

Create another process order of order type PI01 in plant 1100. This time, use the order created in 8-1 as a template to copy from.


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Enter 16,000 pieces as the total quantity you want to produce and Today + 1 week as the basic start date. a)

(…) → Process Order → Process Order → Create → With Material Production plant:

1100

Process order type:

PI01

Template Process order:

Order number from exercise 8-1

Choose Enter. The system creates a new order by copying from the order created in exercise 8-1. Change the total quantity: Total quantity:

16,000 PC

Enter the following basic start date: Start:

Today + 1 week

Choose Enter. The system schedules the process order.

Task 10: 1.

Now create a process order of process order type PI01 in plant 1100 without reference to a material. Create the order with reference to recipe 1 Clean-out of recipe group T-CLEAN. Enter 1 PU (activity unit) as the total quantity and any start date you wish.


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In the distribution rules of the settlement rule, define cost center 4271 Production food as the settlement receiver for the clean-out order. a)

(…) → Process Order → Process Order → Create → Without Material Recipe group:

T-CLEAN

Recipe:

1

Plant:

1100

Process order type:

PI01

Choose Enter. The Create Process Order: Header – General Data screen appears. Total quantity:

1 PU

Start:

Any start date in the future

If applicable, choose Header → Settlement rule. The Maintain Settlement Rule: Overview screen appears. Type:

CTR

Destination:

4271

Enter Choose Back to go back to the order header.

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Lesson Summary You should now be able to: • Use the different options for creating a process order • Explain the activities involved in process order creation

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Lesson: Master Data Selection Lesson Overview This lesson familiarizes you with the process and the settings of master data selection for process orders.

Lesson Objectives After completing this lesson, you will be able to: • • • • • • • •

Define order types and order type-dependent parameters in Customizing Make the appropriate Customizing settings for master data selection Make the appropriate material master settings for selection using a production version Explain the selection using a production version in manual process order creation and planned order conversion Use the production version selection based on a quota arrangement Select production versions manually Read production versions Include master recipes

Business Example You have to complete various scenarios of master data selection for process orders in your company. You proceed in the following way: • • • • •

•

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You will define a process order type in Customizing and get an overview of the order type-dependent parameters. You will make settings for master data selection at order creation in Customizing and the material master. You will make certain settings for a material to determine that a production version is selected based on a quota arrangement. You will test the function for manual production version creation when you create a process order without a planned order. In addition, you will test the Read Master Data function, which you can use to read a different or up-to-date production version in the process order at a later stage. Finally, you will test the Include Master Recipe function, which you can use to include any master recipe in the order at a later stage.


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Lesson: Master Data Selection

Order Type: Customizing

Figure 24: Order type: Customizing

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The following Customizing activities are basic prerequisites for using process orders: •

Customizing: Define order types – –

– •

Customizing: Define order type-dependent parameters – –

– –

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An order type contains control information that you need to manage orders. An order category is assigned to every order type. Order categories are assigned to specific applications in the SAP system. They determine the technical properties of orders. Order category 40 is used for process orders. You must assign a number range to every order type.

In this activity, you determine the parameters that are valid for each order type and plant. Master data: Here, you define the data that influences production version and master recipe selection as well as order master data maintenance. Controlling: Here, you define the parameters relevant to costing, such as costing variants for planned and actual costs. Other settings that you can make refer, for example, to the documentation of status changes, the connection of the Logistics Information System, and the documentation of goods movements.


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Master Data Selection

Figure 25: Master Data Selection

For the creation of a process order and a planned order, a suitable production version is to be determined for the material based on the Validity Period and the Charge Quantity Range. A production version determines which alternative BOM is used in combination with which master recipe for production. Prerequisites and process: •

Creation with planned order: –

–

•

Creation without planned order: – –

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For a production version to be used during planned order creation, alternative selection 3 Selection only by Production Version (recommended) or 2 Selection by Production Version must be defined in the material's MRP data. When converting a planned order, the production version that was determined for the planned order is made known to the process order (and not determined again) and taken over to the corresponding recipe. The BOM is not read again, but rather the dependent requirements of the planned order are converted to reservations for the process order.

The BOM application for the process order type must include the selection of a production version (Customizing). When the order is created, a production version is determined, and the recipe and BOM for the production version are taken over to the process order.


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Planned Order Creation with Production Version

Figure 26: Planned Order Creation with Production Version

When a planned order is converted, the production version is taken over from the planned order to the process order. For a production version to be used during planned order creation, alternative selection 2 Selection by Production Version or 3 Selection only by Production Version (recommended) must be defined in the material's MRP data. Note the following: •

•

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If the system cannot determine a valid production version for a planned order, the system always tries to create the planned order without a production version (BOM determination without production version). When a planned order without production version is converted, the process order cannot be introduced to a production version. This means that no production version can be determined for the process order.


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Production Version Assignment

Figure 27: Production Version Assignment

Based on the criteria Validity Period and Charge Quantity Range, production versions can be assigned to a planned order or process order automatically or manually. If several production versions are valid at the same time according to the criteria Validity Period and Charge Quantity Range: •

•

•

The system always assigns the first valid production version to a planned order, if the assignment is not controlled by quota arrangements. You can change the assignment manually. Note the following: When you need to Convert Planned Order, the production version that was determined for the planned order is always automatically assigned to the process order (and not determined again). With Creation Without Planned Order, you can always select the production version manually in the dialog. –

•

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If the Customizing setting Manual Selection of Production Version was made, you always select the production version in the dialog once a material has more than one valid production version. – If the Customizing setting Automatic Selection of Production Version was made, the first valid production version is automatically assigned to the process order, unless the assignment is controlled through quota arrangements and you have not explicitly called up manual selection in the dialog. In all cases, you can manually change the production version assignment to the process order by choosing the Read Master Data function.


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Checks in Process Order

Figure 28: Checks in Process Order

The graphic provides a detailed overview of the checks that are carried out in the process order during master data selection. First, a valid production version for the material to be produced is determined or the production version introduced through the planned order is checked. (When a planned order is converted, the production version is adopted from the planned order to the process order.) The system then checks the validity periods of the corresponding recipe and bill of material (BOM) for the production version determined. If the system does not find a valid production version, you can cancel the master data selection and thereby the order creation by selecting the material master setting selection only by production version (Alternative Selection Method field). With the other setting, the system tries to select a recipe and a BOM without a production version. If the system is unable to find a valid recipe for the production version, the process can be continued in several different ways depending on the settings made in Customizing. Recipe selection and order creation are either terminated, or an order is created with one operation. In the latter case, you must manually maintain the operation overview afterwards. If the system is unable to find a valid BOM, you can create an order without a BOM. In this case, you can manually assign material components afterwards.

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Selection Settings for the Process Order (I)

Figure 29: Selection Settings for the Process Order (I)

Customizing: Define order type-dependent parameters •

• •

Production version: This parameter specifies whether a production version is selected automatically or manually for the process order when a process order is created without a planned order. Recipe selection: This parameter specifies whether a master recipe is selected for a process order and how it is to be selected. BOM application: This parameter determines how the alternative BOM is selected if a process order is created without a planned order.

Customizing: Define applications • •

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In this activity, you define the procedure for alternative BOM determination. For process manufacturing, make sure that the ProdVers indicator has been set. It specifies that a valid production version is the selection criterion for master data selection when a process order is created without a planned order.


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Selection Settings for the Process Order (II)

Figure 30: Selection Settings for the Process Order (II)

You can specify that the selection of production versions for the process order are automatic or manual when a process order is created without a planned order. • •

You do so in Customizing for Process Orders (order type-dependent parameters, Production Version field). A prerequisite for this is that one of the following settings was made for the selection method (material master, MRP4 view, Alternative Selection Method field): – –

Selection by production version Selection only by production version (recommended)

This setting ensures that process orders can only be created based on a production version.

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Consistency of a Production Version

Figure 31: Consistency of a Production Version

In order for a production version to be consistent, it must fulfill the following requirements: •

•

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The lot-size range of the production version must be in the lot-size range of the assigned recipe as well as that of the assigned alternative BOM. This applies to all change statuses of the recipe and alternative BOMs that are within the validity period of the production version. The assigned recipe and alternative BOMs must exist during the whole validity period of the production version. The deletion flag must not be set for them.


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Production version: Consistency Check

Figure 32: Production version: Consistency Check

You can check whether the data of a production version is consistent with the data of the master recipe and the data of the alternative BOM assigned to it. You can then be sure that a valid recipe or valid BOM actually exists within the whole validity period of the production version. You can trigger the check as follows: • • •

In the Production Versions transaction, for a worklist of selected production versions In the material and recipe for individual production versions In a mass check for all production versions for a material, recipe, or an alternative BOM

If an inconsistency is detected during the check, an error or warning message is displayed in a log on the check result. The check results are updated in the production version as a check status.

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Selection Based on a Quota Arrangement

Figure 33: Selection Based on a Quota Arrangement

You can maintain a quota arrangement to control which production version is to be used up to which quantity produced or with which priority.

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To select by quota arrangement: •

•

•

Maintain the quota arrangement details in Customizing (Process Order -> Operations -> Quota Arrangement): Number ranges and quota arrangement usage Enter a quota arrangement usage that includes production and process orders in the MRP 2 view in the material master of the material to be produced, and choose Selection only by Production Version as the alternative selection method. Maintain the quota arrangement for the material (you can do this, for example, via the process order menu). Enter the following: – – – – –

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E (internal procurement) as the procurement type, E (in-house production) as the special procurement type The production versions that are valid for the quota arrangement period selected The quotas for the usage of the production versions (will be overridden by priorities) If required, a maximum quantity per production version. The production version is not used any more after reaching this quantity. If required, a priority, whereby only the production version for which the lowest value was entered as not equal to zero (highest priority = 1) is used. If a maximum quantity was also entered, the production version with the next higher priority is used after reaching this quantity.


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Exercise 9: Order Type Exercise Objectives After completing this exercise, you will be able to: • Define order types • Define order type-dependent parameters

Business Example You will define a process order type in Customizing and get an overview of the order type-dependent parameters.

Task 1: Create order type PO## along with the description Proc.order, int. number assignmt, grp ## in Customizing. 1.

Create order type PO## along with the description Proc.order, int. number assignmt, grp ## in Customizing.

2.

Define settlement profile PI01 for your order type. Use F1 help for information on the settlement profile functions and on the other parameters and control indicators for the order type. Save your settings.

3.

Assign your order type to the number range PI orders.

Task 2: 1.

Define the order type-dependent parameters for your order type PO## in Customizing for plant 1100. To do so, copy the parameters for order type L310 of plant 1100. Here you are able to get the first overview of the parameters and control indicators you can define. If required, use F1 help.

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Solution 9: Order Type Task 1: Create order type PO## along with the description Proc.order, int. number assignmt, grp ## in Customizing. 1.

Create order type PO## along with the description Proc.order, int. number assignmt, grp ## in Customizing. a)

Tools → Customizing → IMG → Execute Project Press SAP Reference IMG / Production Planning Process Industries → Process Order → Master Data → Order → Define Order Type Choose New Entries.

2.

Order category:

40 (cannot be changed)

Order type:

PO## Proc.order, int. no. assignmt, grp ##

Define settlement profile PI01 for your order type. Use F1 help for information on the settlement profile functions and on the other parameters and control indicators for the order type. Save your settings. a)

Enter the following data in the Profiles for controlling area group box: Settlement profile: PI01 Save your settings.


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3.

Assign your order type to the number range PI orders. a)

Choose Number Range General. The Maintain Number Range Groups screen appears. Select Number Range Process Orders. The order types that have not yet been assigned to a number range are displayed at the end of the list. Position the cursor on your order type PO## and choose Edit → Select Element. Then choose Edit → Assign Element Group. Your order type is assigned to the Process Orders number range. Check this. Save your number range assignment. Choose Enter to confirm the information about the transport of number range intervals. Choose Back to get back to order type maintenance. Choose Back again to exit the screen.

Task 2: 1.

Define the order type-dependent parameters for your order type PO## in Customizing for plant 1100. To do so, copy the parameters for order type L310 of plant 1100. Here you are able to get the first overview of the parameters and control indicators you can define. If required, use F1 help. a)

Customizing: (…) → Process Order → Master Data → Order → Define Order Type-Dependent Parameters Select the line for order type L310 and plant 1100. Choose Edit → Copy as. The view appears as “Process Order Dependant Parameter” change: Details Selected Sets. Overwrite order type L310 with your order type PO##. Choose Enter. The system copies the data. Save your order type-dependent parameters.

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Exercise 10: Master Data Selection Exercise Objectives After completing this exercise, you will be able to: • Make the appropriate Customizing settings for master data selection • Make the appropriate material master settings for selection using a production version • Explain the selection using a production version in manual process order creation and planned order conversion

Business Example You will make settings for master data selection at order creation in Customizing and the material master.

Task 1: Display the order type-dependent parameters for plant 1100 and order type PO## in Customizing. 1.

Display the order type-dependent parameters for plant 1100 and order type PO## in Customizing.

2.

Which settings have been maintained for production version selection? Production version:

3.

Which options for production version selection are available?

4.

Which task list type is selected when a process order is created? TL type:

5.

Which settings have been maintained for master recipe selection? Master Recipe Selection:

6.

Which other options for recipe selection are available?

7.

On the Planning tab, choose the Bill of Material application Process manufacturing for alternative BOM determination.

Task 2: Display the parameters that have been defined for application PI01 Process manufacturing in Customizing for BOM selection. 1.

Display the parameters that have been defined for application PI01 Process manufacturing in Customizing for BOM selection. Continued on next page

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2.

Has the ProdVers indicator been set for application PI01 Process manufacturing?

3.

Which function does this indicator have?

Task 3: Display the MRP 4 view for material T-FI1## in plant 1100. 1.

Display the MRP 4 view for material T-FI1## in plant 1100.

2.

Which production version has been defined for the material? ______________________________________________________ ______________________________________________________ Display the detail data about the production version. Which information does it provide? Write down the valid lot-size range: From lot size: ________________ To lot size: ________________ Write down the validity period: Valid from: ________________ Valid to: ________________ Write down the master data assigned: Task List Type: ________________ Group: ________________ Group Counter: ________________ Alternative BOM: ________________

Task 4: Create a process order of order type PO## for material T-FI1## in plant 1100. Enter 10,000 pieces as the total quantity you want to produce and Today + 1 week as the basic finish date. 1.

Create a process order of order type PO## for material T-FI1## in plant 1100. Enter 10,000 pieces as the total quantity you want to produce and Today + 1 week as the basic finish date.

2.

After the order has been created, display the data on master data selection. Write down the following: Continued on next page

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Production Vers.: ___________________________________________ Master Recipe Recipe Group: __________________________________________ Recipe: _______________________________________________ Bill of Material Alternative:____________________________________________ 3.

Why has the system used a valid production version as the criterion for selecting the required master data for order creation? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

4.

In our example, the production version’s lot-size range refers to the unit KG. In the order, the quantity of material T-FI1## is given in PC (pieces). How does the system convert the two units of measure for material T-FI1##? For the definition of this conversion, refer to the material master record. ______________________________________________________

5.

Check whether the system has correctly transferred the operation and phase data along with the material list for your order. To do so, create a second session and compare the relevant data of the process order and master recipe.

Task 5: Try to create another process order of order type PO## for material T-FI1##. Enter the order quantity 2000 pieces and Today + 1 week as the basic finish date. 1.

Try to create another process order of order type PO## for material T-FI1##. Enter the order quantity 2000 pieces and Today + 1 week as the basic finish date.

2.

Which error message does the system issue? Why? ______________________________________________________ ______________________________________________________


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Display the MRP 4 view for material T-FI1## in plant 1100.

2.

Which setting has been made in the Selection method field? ______________________________________________________

3.

Which function do the settings 2 Selection by production version and 3 Selection only by production version have with regard to the creation of planned orders and process orders? Use field help (F1) to answer this question. ______________________________________________________ ______________________________________________________ ______________________________________________________

Task 7: Create a planned order for material T-FI1##. Use planned order profile LA Stock order. 1.

Create a planned order for material T-FI1##. Use planned order profile LA Stock order.

2.

Select the MRP area 1100 (=plant 1100) Enter 5000 KG as the order quantity and Today + 2 weeks as the order finish date. Save the planned order and write down the order number: ______________________________________________________

3.

Display the planned order once again. Which production version was used to find the BOM for determining component requirements? ______________________________________________________

4.

Which setting causes the BOM to be selected using a valid production version for the material?

Task 8: Convert the planned order you created in exercise 7 to a process order. Use process order type PO##. 1.

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Convert the planned order you created in exercise 7 to a process order. Use process order type PO##. Continued on next page


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2.

After converting, display the data on master data selection. Which production version was used to select the master data? Why? ______________________________________________________ ______________________________________________________ Hint: Selection by production version •

•

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To specify that you want the system to use the valid production version for the material to select component requirements when you create a planned order, you must enter selection method 2 Selection by production version or 3 Selection only by production version (recommended) in the material master record. When converting the planned order to a process order, the system always takes over the production version defined in the planned order and uses it to select the recipe. To specify that for manual process order creation or creation without a planned order you want the system to use the valid production version to select the master data for a material, you must assign an application for BOM selection in the relevant order type-dependent parameters in Customizing. You must set the ProdVers indicator for this application.


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Solution 10: Master Data Selection Task 1: Display the order type-dependent parameters for plant 1100 and order type PO## in Customizing. 1.

Display the order type-dependent parameters for plant 1100 and order type PO## in Customizing. a)

Customizing: (…) → Process Order → Master Data → Order → Define Order Type-Dependent Parameters Double-click on the line for plant 1100 and order type PO##.

2.

Which settings have been maintained for production version selection? Production version: a)

The Master Data tab appears. Production version: Automatic selection of production version

3.

Which options for production version selection are available? a)

4.

Use possible help entries (F4) for the Production Version field to answer this question.

Which task list type is selected when a process order is created? TL type: a)

5.

TL type: Master Recipe

Which settings have been maintained for master recipe selection? Master Recipe Selection: a)

Master Recipe Selection: Master recipe mandatory (automatic selection)

6.

Which other options for recipe selection are available? a)

7.

Use possible help entries (F4) for the Master Recipe Selection field to answer this question.

On the Planning tab, choose the Bill of Material application Process manufacturing for alternative BOM determination. a)

Choose the Planning tab. Bill of Material application: Process manufacturing Save your order type-dependent parameters. Continued on next page

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Task 2: Display the parameters that have been defined for application PI01 Process manufacturing in Customizing for BOM selection. 1.

Display the parameters that have been defined for application PI01 Process manufacturing in Customizing for BOM selection. a)

2.

Has the ProdVers indicator been set for application PI01 Process manufacturing? a)

3.

Customizing: (…) → Process Order → Operations → BOM Selection → Define Applications

The ProdVers indicator has been set for application PI01.

Which function does this indicator have? a)

The indicator must be set if you want the system to use a valid production version to select master data when you create a process order without a planned order.


Display the MRP 4 view for material T-FI1## in plant 1100. a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-FI1## Enter Go to the MRP 4 view. Enter Go to plant 1100. Enter

2.

Which production version has been defined for the material? ______________________________________________________ ______________________________________________________ Display the detail data about the production version. Which information does it provide? Write down the valid lot-size range: From lot size: ________________ Continued on next page

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To lot size: ________________ Write down the validity period: Valid from: ________________ Valid to: ________________ Write down the master data assigned: Task List Type: ________________ Group: ________________ Group Counter: ________________ Alternative BOM: ________________ a)

Choose ProdVersion. Version: 0001 Ice cream production Double-click the production version number. From lot size: 2,000 kg To lot size: 10,000 kg Task List Type: Master Recipe Group: T-ICE## Group Counter: 1 Alternative BOM: 1

Task 4: Create a process order of order type PO## for material T-FI1## in plant 1100. Enter 10,000 pieces as the total quantity you want to produce and Today + 1 week as the basic finish date. 1.

Create a process order of order type PO## for material T-FI1## in plant 1100.


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Enter 10,000 pieces as the total quantity you want to produce and Today + 1 week as the basic finish date. a)

Logistics → Production-Process → Process Order → Process Order → Create → With Material Material no.:

T-FI1##

Production plant:

1100

Process order type:

PO##

Choose Enter. The Create Process Order: Header – General Data screen appears.

2.

Total qty:

10,000 PC

Finish:

Today + 1 week

After the order has been created, display the data on master data selection. Write down the following: Production Vers.: ___________________________________________ Master Recipe Recipe Group: __________________________________________ Recipe: _______________________________________________ Bill of Material Alternative:____________________________________________ a)

Choose the Mast. data tab. Production Vers.: 0001 Master Recipe Recipe Group: T-ICE## Recipe: 1 Bill of Material Alternative 1

3.

Why has the system used a valid production version as the criterion for selecting the required master data for order creation? ______________________________________________________ ______________________________________________________ Continued on next page

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______________________________________________________ ______________________________________________________ a)

The ProdVers indicator for the BOM application PI01 Process Manufacturing determines that a valid production version is used to select master data (see exercise 2-3-2). Save the order.

4.

In our example, the production version’s lot-size range refers to the unit KG. In the order, the quantity of material T-FI1## is given in PC (pieces). How does the system convert the two units of measure for material T-FI1##? For the definition of this conversion, refer to the material master record. ______________________________________________________ a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-FI1## Enter Go to the Basic Data 1 view. Enter Choose Additional data. Choose Units of measure. 2 PC ⇔ 1 KG

5.

Check whether the system has correctly transferred the operation and phase data along with the material list for your order. To do so, create a second session and compare the relevant data of the process order and master recipe. a) Hint: To create a second session, choose System → Create Session.

Task 5: Try to create another process order of order type PO## for material T-FI1##. Enter the order quantity 2000 pieces and Today + 1 week as the basic finish date. 1.

Try to create another process order of order type PO## for material T-FI1##. Continued on next page

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Enter the order quantity 2000 pieces and Today + 1 week as the basic finish date. a)


T-FI1##

Production plant:

1100

Process order type:

PO##

Choose Enter. The Create Process Order: Header – General Data screen appears. Total qty:

2000 PC

Finish:

For example: Today + 1 week

Enter 2.

Which error message does the system issue? Why? ______________________________________________________ ______________________________________________________ a)

No valid production version exists for the selection criteria because the total quantity of 2,000 PC you have entered is outside the valid charge quantity range of the production version for material T-FI1##.


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Display the MRP 4 view for material T-FI1## in plant 1100. a)

Logistics → Production - Process → Master Data → Material Master → Material→ Display→ Display Current Material:

T-FI1##

Enter Go to the MRP 4 view. Enter Go to Plant 1100. Enter 2.

Which setting has been made in the Selection method field? ______________________________________________________ a)

3.

Selection method: 3 Selection only by production version

Which function do the settings 2 Selection by production version and 3 Selection only by production version have with regard to the creation of planned orders and process orders? Use field help (F1) to answer this question. ______________________________________________________ ______________________________________________________


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______________________________________________________ a)

Material requirements planning, Selection method 2 and 3: When you create a planned order, the system uses the valid production version for the material to select the component requirements. Note: If the system cannot determine a production version, it tries to select a BOM for the planned order without reference to a production version. Process order creation, Selection method 3: If the system does not find a valid production version, you cannot create process orders. Note: If Selection method 3 is not defined when you create a process order without a planned order and if the system cannot determine a valid production version, it tries to select a valid recipe and BOM without reference to a production version.

Task 7: Create a planned order for material T-FI1##. Use planned order profile LA Stock order. 1.

Create a planned order for material T-FI1##. Use planned order profile LA Stock order. a)

Logistics → Production Process → MRP → Planned Order → Create Plnned order profile:

LA

Enter 2.

Select the MRP area 1100 (=plant 1100) Enter 5000 KG as the order quantity and Today + 2 weeks as the order finish date. Save the planned order and write down the order number:


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______________________________________________________ a) Material:

T-FI1##

MRP area:

1100

Order quantity:

5000

Ord.finish:

Today +2 weeks

Save your planned order. The order number is displayed after you have saved the order. 3.

Display the planned order once again. Which production version was used to find the BOM for determining component requirements? ______________________________________________________ a)

(…) → MRP →Planned Order → Display → Individual Display Planned order:

Order number

Enter Production Version: 4.

0001

Which setting causes the BOM to be selected using a valid production version for the material? a)

The selection method in the material master controls this (see exercise 6-3)..

Task 8: Convert the planned order you created in exercise 7 to a process order. Use process order type PO##. 1.

Convert the planned order you created in exercise 7 to a process order. Use process order type PO##. a)

(…) → MRP → Planned Order → Convert to Proc. Ord. → Individual Conversion Planned Order:


Process Order Type:

PO## Continued on next page

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2.

After converting, display the data on master data selection. Which production version was used to select the master data? Why? ______________________________________________________ ______________________________________________________ Hint: Selection by production version •

•

a)

To specify that you want the system to use the valid production version for the material to select component requirements when you create a planned order, you must enter selection method 2 Selection by production version or 3 Selection only by production version (recommended) in the material master record. When converting the planned order to a process order, the system always takes over the production version defined in the planned order and uses it to select the recipe. To specify that for manual process order creation or creation without a planned order you want the system to use the valid production version to select the master data for a material, you must assign an application for BOM selection in the relevant order type-dependent parameters in Customizing. You must set the ProdVers indicator for this application.

Choose Enter. The system converts the planned order to a process order. This display appears Create Process Order: Header– General Data. Choose the Mast. data tab. Production Vers.:

0001

When converting a planned order to a process order, the system always uses the production version defined in the planned order to select the corresponding recipe.

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Exercise 11: Production Version Selection Based on a Quota Arrangement Exercise Objectives After completing this exercise, you will be able to: • Define a selection of production versions based on quotas • Define a selection of production versions based on priorities

Business Example You will make certain settings for a material to determine that a production version is selected based on a quota arrangement.

Task 1: Display the MRP 2 and MRP 4 views for your material T-CERM-## in plant 1100. 1.

Display the MRP 2 and MRP 4 views for your material T-CERM-## in plant 1100.

2.

Write down the following information from the MRP 2 view: Quota arrangement usage: ______________________________________________________ Does the quota arrangement usage maintained allow you to maintain quotas for the business transaction Process order creation? Use F1 and F4 help to answer the question. ______________________________________________________ ______________________________________________________

3.

Write down the following information from the MRP 4 view: Selection method: ______________________________________________________

4.

Which production versions have been maintained for the material? ______________________________________________________ Display the detailed information for every production version.


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Task 2: Create a quota arrangement for material T-CERM-## in plant 1100. 1.

Create a quota arrangement for material T-CERM-## in plant 1100.

2.

Enter a quota arrangement period until, for example, the end of the year.

3.

Make the following entries in the item overview:

4.

P

S

PVer Quota

E

E

0001 50

E

E

0002 50

Alloc. qty.

Maximum quantity

Priority

Save your quota arrangement.

Task 3: Create a process order for material T-CERM-## in plant 1100. Use order type PO##. 1.

Create a process order for material T-CERM-## in plant 1100. Use order type PO##.

2.

3.

Total qty:

1,000 kg

Finish:

for example: Today + 1 week

Which production version and quota arrangement item was used to create the order? ______________________________________________________ ______________________________________________________ Save the order.

Task 4: Display your quota arrangement for material T-CERM-## in plant 1100. 1.

Display your quota arrangement for material T-CERM-## in plant 1100.

2.

Write down the quota-allocated quantity in the following table:


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P

S

PVer Quota

E

E

0001 50

E

E

0002 50

Alloc. qty.

Maximum quantity

Priority

Task 5: Create another process order for material T-CERM-##. 1.

2.

Total qty:

3,000 kg

Basic date:

Today + 1 week

Which production version was used to create the order? ______________________________________________________ Save the order.

Task 6: Create another process order for material T-CERM-##. 1. Total qty.: 2.

1,000 kg


Task 7: Create another process order for material T-CERM-##. 1. Total qty: 2.

2,000 kg

Which production version was used to create the order? ______________________________________________________ Save the order. Continued on next page

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2.

Write down the quota-allocated quantities in the following table: P

S

PVer Quota

E

E

0001 50

E

E

0002 50

Alloc. qty.

Maximum quantity

Priority

Interpret the results for the exercises 2 to 8: ______________________________________________________ ______________________________________________________ ______________________________________________________

Task 9: Change your quota arrangement for material T-CERM-##. 1.

Change your quota arrangement for material T-CERM-##.

2.

Make the following entries in the item overview with regard to the priorities and maximum quantities:

3.

P

S

PVer Quota

Alloc. qty.

Maximum quantity

Priority

E

E

0001 50

4000

10000

1

E

E

0002 50

3000

2



2.

Total qty:

3,000 kg

Basic date:

Today + 1 week

Which production version was used to create the order? ______________________________________________________ Continued on next page

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Save the order.


2.

Total qty:

4,000 kg

Basic date:

Today + 1 week



2.

Total qty:

3,000 kg

Basic date:

Today + 1 week



2.

Write down the quota-allocated quantities in the following table: P

S

PVer Quota

E

E

0001 50

E

E

0002 50

Alloc. qty.

Maximum quantity

Priority

10000

1 2

Interpret the results for the exercises 9 to13:


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Task 14: 1.

128

Delete the quota arrangement usage assigned in the MRP 2 view for your material T-CERM-##.


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Solution 11: Production Version Selection Based on a Quota Arrangement Task 1: Display the MRP 2 and MRP 4 views for your material T-CERM-## in plant 1100. 1.

Display the MRP 2 and MRP 4 views for your material T-CERM-## in plant 1100. a)

Logistics → Production - Process → Master Data → Material Master → Material→ Display→ Display Current Material:

T-CERM-##

Enter Choose the views MRP 2 and MRP 4. Enter Go to plant 1100. Enter 2.

Write down the following information from the MRP 2 view: Quota arrangement usage: ______________________________________________________ Does the quota arrangement usage maintained allow you to maintain quotas for the business transaction Process order creation? Use F1 and F4 help to answer the question. ______________________________________________________ ______________________________________________________ a)

MRP 2 view: Quota arrangement usage: 4 The quota arrangement usage selected enables a quota arrangement with regard to process order creation. The total quantity of all process orders for this material is used in the quota arrangement. F4 help: The Ord indicator is set.

3.

Write down the following information from the MRP 4 view: Continued on next page

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Selection method: ______________________________________________________ a)

MRP 4 view: Selection method: 3 Selection only by production version Hint: This setting must be made if the above quota arrangement usage is to become effective with regard to process orders for this material.

4.

Which production versions have been maintained for the material? ______________________________________________________ Display the detailed information for every production version. a)

MRP 4 view: Choose ProdVersion. Production versions 0001 and 0002 exist for the material. The lot-size ranges are identical for both production versions.

Task 2: Create a quota arrangement for material T-CERM-## in plant 1100. 1.

Create a quota arrangement for material T-CERM-## in plant 1100. a)

2.

(…)→ Process Order → Environment → Master Data → Quota Maintenance Material:

T-CERM-##

Plant:

1100

Enter a quota arrangement period until, for example, the end of the year. a)

Screen Maintain Quota Arrangement: Overview of Quota Arr. Periods Valid to:

3.

for example, the end of the year

Make the following entries in the item overview:


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P

S

PVer Quota

E

E

0001 50

E

E

0002 50

a)

Alloc. qty.

Maximum quantity

Priority

Goto → Item overview or double-click the line of the valid-to period you have just entered. Screen Maintain Quota Arrangement: Overview of Quota Arr. Items

4.

P S

PVer Quota

E E

0001 50

E E

0002 50

Alloc. qty.

Maximum quantity

Priority

Save your quota arrangement. a)


Task 3: Create a process order for material T-CERM-## in plant 1100. Use order type PO##. 1.

Create a process order for material T-CERM-## in plant 1100. Use order type PO##. a)

Logistics → Production Process → Process Order → Process Order → Create → With Material Material no.:

T-CERM-##

Production plant:

1100

Process order type:

PO##

Choose Enter and the following appears Create Process Order: Header – General Data. 2. Total qty:

1,000 kg

Finish:

for example: Today + 1 week

a)

Choose Enter to confirm your entries. Continued on next page

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Which production version and quota arrangement item was used to create the order? ______________________________________________________ ______________________________________________________ Save the order. a)

Master data tab page: Production Vers.:

0001

Quota arrangement:

Quota arrangement number/item

Save your order.


Display your quota arrangement for material T-CERM-## in plant 1100. a)

2.

(…)→ Process Order → Environment → Master Data → Quota Maintenance Material:

T-CERM-##

Plant:

1100

Write down the quota-allocated quantity in the following table:


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P

S

PVer Quota

E

E

0001 50

E

E

0002 50

a)

Alloc. qty.

Maximum quantity

Priority

Screen Maintain Quota Arrangement: Overview of Quota Arr. Periods Goto → Item overview or double-click the line of the valid-to period you have just entered. Screen Maintain Quota Arrangement: Overview of Quota Arr. Items P S

PVer Quota Alloc. qty.

E E

0001 50

E E

0002 50

Maximum quantity

Priority

1000

Task 5: Create another process order for material T-CERM-##. 1. Total qty:

3,000 kg

Basic date:

Today + 1 week

a) 2.

See exercise

Which production version was used to create the order? ______________________________________________________ Save the order. a) Production version:

0002



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Total qty.: a) 2.

1,000 kg

See exercise


0001

Task 7: Create another process order for material T-CERM-##. 1. Total qty: a) 2.

2,000 kg

See exercise


0001


Write down the quota-allocated quantities in the following table:


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P

S

PVer Quota

E

E

0001 50

E

E

0002 50

Alloc. qty.

Maximum quantity

Priority

a)

2.

P S

PVer Quota

Alloc. qty.

E E

0001 50

4000

E E

0002 50

3000

Maximum quantity

Priority

Interpret the results for the exercises 2 to 8: ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

Due to the quota arrangement you have created for material T-CERM-##, the system attempts to distribute the process order quantities between the two production versions 0001 and 0002 in a 50:50 ratio. It creates a process order for the production version with the smallest quota-allocated quantity.

Task 9: Change your quota arrangement for material T-CERM-##. 1.

Change your quota arrangement for material T-CERM-##. a)

2.

(…)→ Process Orders → Environment → Master Data → Quota Maintenance Material:

T-CERM-##

Plant:

1100

Make the following entries in the item overview with regard to the priorities and maximum quantities:


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P

S

PVer Quota

Alloc. qty.

Maximum quantity

Priority

E

E

0001 50

4000

10000

1

E

E

0002 50

3000

a)

2

Screen Maintain Quota Arrangement: Overview of Quota Arr. Periods Goto → Item overview or double-click the line of the valid-to period you have just entered. Screen Maintain Quota Arrangement: Overview of Quota Arr. Items

3.

P S


Maximum quantity

Priority

E E

0001 50

4000

10000

1

E E

0002 50

3000

2

Save your quota arrangement. a)



3,000 kg

Basic date:

Today + 1 week

a) 2.

See exercise


0001


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4,000 kg

Basic date:

Today + 1 week

a) 2.

See exercise


0001


3,000 kg

Basic date:

Today + 1 week

a) 2.

See exercise


0002


Write down the quota-allocated quantities in the following table:


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P

S

PVer Quota

E

E

0001 50

E

E

0002 50

Alloc. qty.

Maximum quantity

Priority

10000

1 2

a)

2.

P S


Maximum quantity

Priority

E E

0001 50

11000

10000

1

E E

0002 50

6000

2

Interpret the results for the exercises 9 to13: a)

Due to the changes you have made to the quota arrangement for material T-CERM-##, the system first only takes production version 0001 with the lowest value of priority 1 into account. If the maximum quantity of 10,000 is reached or exceeded, production version 0001 is no longer used. Production version 0002 with the next higher priority 2 is now used.

Task 14: 1.

Delete the quota arrangement usage assigned in the MRP 2 view for your material T-CERM-##. a)

(…) → Material → Change → Immediately Material:

T-CERM-##

MRP 2 view:

138

Plant:

1100

Quota arrangement usage:

__


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Exercise 12: Manual Production Version Selection Exercise Objectives After completing this exercise, you will be able to: • Use the manual selection of production versions for creating orders without a planned order • Read a production version in the order • Include a master recipe in the order

Business Example You will test the function for manual production version creation when you create a process order without a planned order. In addition, you will test the Read Master Data function, which you can use to read a different or up-to-date production version in the process order at a later stage. Finally, you will test the Include Master Recipe function, which you can use to include any master recipe in the order at a later stage.

Task: 1.

In the order type-dependent parameters for your order type PO## in plant 1100, choose the setting: Production version:

2.

Manual selection of production version

Create a process order for material T-CERM-## with reference to your order type PO## in plant 1100. Total qty:

1,000 kg

Basic date:

Today + 1 week

Note that you must select a production version in the dialog mode. 3.

In the order type-dependent parameters for your order type PO## in plant 1100, choose the setting:


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Production version:

4.

Automatic selection of production version

Create another process order for material T-CERM-## with reference to your order type PO## in plant 1100. Total qty:

1,000 kg

Basic date:

Today + 1 week

Note that the first production version is now used automatically. 5.

Create yet another process order. Total qty:

1,000 kg

Basic date:

Today + 1 week

Before confirming your entries on the date and quantities, choose Production version. You can now select a production version in the dialog mode. Select production version 0002 and save the order. 6.

Change the order you created in exercise 1-5. Change the production version by using the Read master data function. Read production version 0001.

7.

Change the order once again. Navigate to the Operation overview and include master recipe 1 of recipe group T-CLEAN for plant 1100.

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Solution 12: Manual Production Version Selection Task: 1.


a) 2.

Manual selection of production version

Customizing: (…) → Process Order → Master Data → Order → Define Order Type-Dependent Parameters

Create a process order for material T-CERM-## with reference to your order type PO## in plant 1100. Total qty:

1,000 kg

Basic date:

Today + 1 week

Note that you must select a production version in the dialog mode. a) 3.

Logistics → Production Process → Process Order → Process Order → Create → With Material


a) 4.

Automatic selection of production version

See exercise 1-1

Create another process order for material T-CERM-## with reference to your order type PO## in plant 1100. Total qty:

1,000 kg

Basic date:

Today + 1 week

Note that the first production version is now used automatically. a) 5.

See exercise 1-2

Create yet another process order. Continued on next page

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Total qty:

1,000 kg

Basic date:

Today + 1 week

Before confirming your entries on the date and quantities, choose Production version. You can now select a production version in the dialog mode. Select production version 0002 and save the order. a) 6.

See exercise 1-2

Change the order you created in exercise 1-5. Change the production version by using the Read master data function. Read production version 0001. a)

In the order, choose: Process order → Functions → Read master data

7.

Change the order once again. Navigate to the Operation overview and include master recipe 1 of recipe group T-CLEAN for plant 1100. a)

In the operation overview for the order, choose: Operation → Include master recipe ...

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Lesson Summary You should now be able to: • Define order types and order type-dependent parameters in Customizing • Make the appropriate Customizing settings for master data selection • Make the appropriate material master settings for selection using a production version • Explain the selection using a production version in manual process order creation and planned order conversion • Use the production version selection based on a quota arrangement • Select production versions manually • Read production versions • Include master recipes

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Lesson: Scheduling Lesson Overview This lesson familiarizes you with the process and settings of scheduling for process orders.

Lesson Objectives After completing this lesson, you will be able to: •

•

Perform the following Customizing activities for scheduling process orders: define scheduling types, set scheduling parameters, define scheduling margins Trace the scheduling of process orders in detail

Business Example You will define scheduling parameters for your order type and a scheduling margin key for your product in Customizing. You will then test different scenarios for process order scheduling in the application.

Scheduling

Figure 34: Scheduling

Starting from the order start or finish dates, process orders are scheduled in forward or backward scheduling. The system determines the planned start and finish dates for the order, and its phases and operations.

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Lesson: Scheduling

Depending on the scheduling type, the float before production is either added to the order start date or the float after production is subtracted from the order finish date to determine the start or finish date of the production (scheduled start date, scheduled finish date). The float before production and float after production are time buffers enabling you to react to malfunctions in the manufacturing process. The system determines the start and finish dates of the phases starting from the scheduled start and finish dates. To do so, it must determine the phase durations and take relationships into account. The release date for the order is determined by subtracting the release period from the scheduled start date. The release date is used as a selection criterion for the collective release of process orders.

Scheduling: Phase Duration

Figure 35: Scheduling: Phase Duration

To calculate the phase duration, you must define a capacity category to be used as the scheduling basis and a formula in the resource. The phase duration is determined on the basis of the standard values and additional formula parameters. When determining the phase dates, the available capacity is taken into account with breaks in the scheduling basis . Scheduling is carried out at the phase level. Operation dates are derived from the phase dates.

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Scheduling: Customizing

Figure 36: Scheduling: Customizing

Customizing: Specify Scheduling Parameters In this activity, you define the parameters for scheduling process orders for each plant, order type, and production scheduler.

Scheduling Margins

Figure 37: Scheduling Margins

Customizing: Define Scheduling Margin Key In this activity, you specify time floats for order scheduling as well as the release period for order release. A suitable scheduling margin key is assigned to a material on the MRP view of its material master.

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Lesson: Scheduling

Exercise 13: Scheduling Exercise Objectives After completing this exercise, you will be able to: • Display the definition of scheduling types in Customizing • Define the setting of scheduling parameters in Customizing • Define a scheduling margin key in Customizing • Explain the scheduling of process orders in the application

Business Example You will define scheduling parameters for your order type and a scheduling margin key for your product in Customizing. You will then test different scenarios for process order scheduling in the application.

Task 1: 1.

Display the scheduling types defined in Customizing. Get an overview of the options you have when defining scheduling types.

Task 2: Define the scheduling parameters for your order type PO## for all production schedulers in plant 1100. To do so, follow the instructions below. Note: Process orders are scheduled in detailed scheduling. The data in the Rate-based scheduling group box (for repetitive manufacturing) and Rough-cut scheduling group box (for rough-cut planning) do not apply to process order management. 1.

Define the scheduling parameters for your order type PO## for all production schedulers in plant 1100. To do so, follow the instructions below.

2.

For the phases of process orders, you want the system to create capacity requirements for the scheduled phase dates.

3.

When the process order dates are changed, you want the system to adjust the basic order dates.

4.

When you create a process order, you want the system to propose scheduling type Forwards by default.

5.

You want the system to always schedule an order every time it is saved. Continued on next page

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SCM340

If required, use the field help (F1) for more information on the other scheduling control parameters for detailed scheduling.

Task 3: Display the scheduling margin keys defined in Customizing. 1.

Display the scheduling margin keys defined in Customizing.

2.

Define scheduling margin key I## for plant 1100 and enter the following data:

3.

Plant

Key

Ope ...

Float After

Float Befor ...

Release P ...

1100

I##

5

1

2

5

Use field help (F1) for information on the meaning of settings for the various time intervals. Save your scheduling margin key.

4.

On the MRP 2 view for plant 1100, assign scheduling margin key I## to your material T-FI1##.

Task 4: Create a process order of order type PO## for material T-FI1## in plant 1100. Enter a total quantity to be produced that is within the valid charge quantity range. 1.

Create a process order of order type PO## for material T-FI1## in plant 1100. Enter a total quantity to be produced that is within the valid charge quantity range.

2.

Which scheduling type does the system propose? Which setting controls this?


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Lesson: Scheduling

3.

Which scheduling margin key does the system use when determining the order dates? Which setting controls this?

4.

Which additional scheduling indicators does the system set on the Control data tab? Which settings control this?

Task 5: Starting from the basic start date, check whether the system has determined the correct dates for the process order you have created in exercise 4. Check the following dates: 1.

Scheduled order start: How did the system determine this date?

2.

Planned phase start dates and phase end dates: How did the system determine these dates? Compare the phase duration and dates that the system has determined with the standard values and phase relationships. If required, create a second session and display the relationships for recipe T-ICE## in the graphic mode.


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3.

Scheduled order finish: How did the system determine this date?

4.

Basic order finish: How did the system determine this date?

5.

Scheduled release date: How did the system determine this date?

6.

Requirement dates of the assigned material components: How did the system determine these requirement dates?

Task 6: In Customizing for the scheduling parameters of plant 1100 and order type PO##, define the following reduction strategy: 1.

In Customizing for the scheduling parameters of plant 1100 and order type PO##, define the following reduction strategy:

2. Maximum reduction level

Do not reduce beyond reduction level 3

% reduction in floats

30

60

100


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Lesson: Scheduling

3.

Use field help (F1) for information on the function and meaning of the reduction strategy above. Save your settings.

Task 7: Create a process order of order type PO## for material T-FI1## in plant 1100. Enter a total quantity to be produced that is within the valid charge quantity range. Choose next Monday (or the first workday of next week) as the basic start date. 1.

Create a process order of order type PO## for material T-FI1## in plant 1100. Enter a total quantity to be produced that is within the valid charge quantity range. Choose next Monday (or the first workday of next week) as the basic start date.

2.

Change the basic order finish to one workday closer to the present. Which new order status has been set? Reschedule the order. Which reduction level does the system use? How does reduction affect the order dates?

3.

Change the basic order finish date to one more workday closer to the present and schedule the order again. Which reduction level does the system use? How does reduction affect the order dates?

4.

Again, change the basic order finish to one workday closer to the present and schedule the order again. Which reduction level does the system use? How does reduction affect the order dates?

5.

Display the scheduling parameters that you can still change in the order. Delete the settings for the reduction strategy and schedule the order again. What does the scheduling result look like?

6.

Now choose scheduling type Backwards and schedule the order again. How does changing the scheduling type affect the order dates? In particular, compare the scheduled production dates with the dates in forward scheduling. Continued on next page

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Now you want to schedule the order again starting from a changed production finish date. Choose the corresponding function in the order and then change the scheduled finish date from 24:00:00 to 20:00:00. Schedule the order again. How do these changes affect the order dates?

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Solution 13: Scheduling Task 1: 1.

Display the scheduling types defined in Customizing. Get an overview of the options you have when defining scheduling types. a)

Customizing: (…) → Process Order → Operations → Scheduling → Specify Scheduling Type

Task 2: Define the scheduling parameters for your order type PO## for all production schedulers in plant 1100. To do so, follow the instructions below. Note: Process orders are scheduled in detailed scheduling. The data in the Rate-based scheduling group box (for repetitive manufacturing) and Rough-cut scheduling group box (for rough-cut planning) do not apply to process order management. 1.

Define the scheduling parameters for your order type PO## for all production schedulers in plant 1100. To do so, follow the instructions below. a)

Customizing: (…) → Process Order → Operations → Scheduling → Specify Scheduling Parameters New Entries

2.

Plant:

1100

Order type:

PO##

ProdScheduler:

*

For the phases of process orders, you want the system to create capacity requirements for the scheduled phase dates. a)

Detailed scheduling X Generate Capacity Reqs.

3.

When the process order dates are changed, you want the system to adjust the basic order dates. a)

Adjust Scheduling Adjust basic dates, adjust dep. reqmts to order start


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When you create a process order, you want the system to propose scheduling type Forwards by default. a)

Scheduling control for detailed scheduling Scheduling Type Forwards

5.

You want the system to always schedule an order every time it is saved. a)

Scheduling control for detailed scheduling X Automatic Scheduling Save your scheduling parameter.

6.

If required, use the field help (F1) for more information on the other scheduling control parameters for detailed scheduling. a)

No further instruction required

Task 3: Display the scheduling margin keys defined in Customizing. 1.

Display the scheduling margin keys defined in Customizing. a)

2.

Define scheduling margin key I## for plant 1100 and enter the following data: Plant

Key

Ope ...

Float After

Float Befor ...

Release P ...

1100

I##

5

1

2

5

a) 3.

Customizing: (…) → Process Order → Operations → Scheduling → Define Scheduling Margin Key

New Entries

Use field help (F1) for information on the meaning of settings for the various time intervals. Save your scheduling margin key. a)



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Lesson: Scheduling

4.

On the MRP 2 view for plant 1100, assign scheduling margin key I## to your material T-FI1##. a)

Logistics → Production Process → Master Data → Material Master → Material → Change → Immediately Material:

T-FI1##

Enter Go to the MRP 2 view. Enter Go to plant 1100. Enter SchedMargin key:

I##

Save your material master record.

Task 4: Create a process order of order type PO## for material T-FI1## in plant 1100. Enter a total quantity to be produced that is within the valid charge quantity range. 1.

Create a process order of order type PO## for material T-FI1## in plant 1100.


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Enter a total quantity to be produced that is within the valid charge quantity range. a)


T-FI1##

Production plant:

1100

Process order type:

PO##

Choose Enter and the following appears Create Process Order: Header – General Data. Total qty:

Quantity within the valid charge quantity range

Start:

For example: Today + 1 week

Enter 2.

Which scheduling type does the system propose? Which setting controls this? Answer: In accordance with the scheduling parameters you have defined in Customizing, the system proposes scheduling type Forwards (see exercise 2-4).

3.

Which scheduling margin key does the system use when determining the order dates? Which setting controls this? Answer: According to the settings you have made in the material master record for material T-FI1##, the system proposes scheduling margin key I## (see exercise 3-4).

4.

Which additional scheduling indicators does the system set on the Control data tab? Which settings control this? Answer: Choose the Control data tab. In accordance with the scheduling parameters you have defined in Customizing, the system sets the Capacity Requirements indicator and the Automatic Scheduling indicator (see exercises 2-2 and 2-5).


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Lesson: Scheduling

Task 5: Starting from the basic start date, check whether the system has determined the correct dates for the process order you have created in exercise 4. Check the following dates: 1.

Scheduled order start: How did the system determine this date? Answer: For some corresponding information on this topic, see the page “Scheduling” in your participant handbook.

2.

Planned phase start dates and phase end dates: How did the system determine these dates? Compare the phase duration and dates that the system has determined with the standard values and phase relationships. If required, create a second session and display the relationships for recipe T-ICE## in the graphic mode. Answer: For some corresponding information on this topic, see the page “Scheduling” in your participant handbook and “Scheduling: Phase Duration”.

3.

Scheduled order finish: How did the system determine this date? Answer: For some corresponding information on this topic, see the page “Scheduling” in your participant handbook.

4.

Basic order finish: How did the system determine this date? Answer: For some corresponding information on this topic, see the page “Scheduling” in your participant handbook.

5.

Scheduled release date: How did the system determine this date? Answer: For some corresponding information on this topic, see the page “Scheduling” in your participant handbook.

6.

Requirement dates of the assigned material components: How did the system determine these requirement dates? Answer: Choose Materials. The requirement dates of the components are displayed in the General Data for the material list items. You can display the General Data, for example, by double-clicking the item number of a material component. The requirement dates are identical to the earliest phase dates according to the material component/phase assignments.


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Task 6: In Customizing for the scheduling parameters of plant 1100 and order type PO##, define the following reduction strategy: 1.

In Customizing for the scheduling parameters of plant 1100 and order type PO##, define the following reduction strategy: a)

Customizing: (…) → Process Order → Operations → Scheduling → Specify Scheduling Parameters Double-click on the line for plant 1100 and order type PO##.

2. Maximum reduction level

Do not reduce beyond reduction level 3

% reduction in floats

30

a) 3.

60

100

Make the settings and save your scheduling parameters.

Use field help (F1) for information on the function and meaning of the reduction strategy above. Save your settings. a)


Task 7: Create a process order of order type PO## for material T-FI1## in plant 1100. Enter a total quantity to be produced that is within the valid charge quantity range. Choose next Monday (or the first workday of next week) as the basic start date. 1.

Create a process order of order type PO## for material T-FI1## in plant 1100. Enter a total quantity to be produced that is within the valid charge quantity range.


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Lesson: Scheduling

Choose next Monday (or the first workday of next week) as the basic start date. a)


T-FI1##

Production plant:

1100

Process order type:

PO##

Choose Enter and the following appears Create Process Order: Header – General Data. Total qty:

Quantity within the valid charge quantity range

Start:

Next Monday (or the first workday of the next week)

Enter 2.

Change the basic order finish to one workday closer to the present. Which new order status has been set? Reschedule the order. Which reduction level does the system use? How does reduction affect the order dates? a)

Choose the Status (i) icon for the status line. Status:

NTUP Dates are not updated

Choose Back. Choose the Schedule order icon. Reduction:

Reduction level 1

The float before production was reduced by one day. As a result, the scheduled start date is now one day closer to the present. 3.

Change the basic order finish date to one more workday closer to the present and schedule the order again. Which reduction level does the system use?


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How does reduction affect the order dates? a) Reduction:

Reduction level 2

The float after production is used up. 4.

Again, change the basic order finish to one workday closer to the present and schedule the order again. Which reduction level does the system use? How does reduction affect the order dates? a) Reduction:

Reduction level 3

The float before production is used up. As a result, the scheduled start date is now one more day closer to the present. 5.

Display the scheduling parameters that you can still change in the order. Delete the settings for the reduction strategy and schedule the order again. What does the scheduling result look like? a)

Choose Process order → Settings → Scheduling parameters... Delete the settings for the reduction strategy and schedule the order again. The system has adjusted the basic order finish in accordance with the corresponding scheduling parameter settings in Customizing (see exercise 2-3).

6.

Now choose scheduling type Backwards and schedule the order again. How does changing the scheduling type affect the order dates? In particular, compare the scheduled production dates with the dates in forward scheduling. a)

Starting from the basic order finish, the system schedules the order backward. As a result, the order receives a new scheduled finish date and due to this, new phase dates as well as a new scheduled start date. The basic order dates stay the same.


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Lesson: Scheduling

7.

Now you want to schedule the order again starting from a changed production finish date. Choose the corresponding function in the order and then change the scheduled finish date from 24:00:00 to 20:00:00. Schedule the order again. How do these changes affect the order dates? a)

On the General data tab of the order header, choose the Change scheduled dates icon in the Dates section. You can now change the scheduled production dates. Change the scheduled finish date from 24:00:00 to 20:00:00 and schedule the order again. The system schedules the order starting from the changed scheduled finish date.

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Lesson Summary You should now be able to: • Perform the following Customizing activities for scheduling process orders: define scheduling types, set scheduling parameters, define scheduling margins • Trace the scheduling of process orders in detail

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Lesson: Costing

Lesson: Costing Lesson Overview This lesson informs you about calculating planned costs for process orders.


Determine the planned costs for a process order.

Business Example You will analyze the planned costs for a process order.

Calculating Planned Costs (I)

Figure 38: Calculating Planned Costs (I)

If you use order-related Cost Object Controlling, a cost object is managed for every single process object. The costs incurred for an order can be calculated manually or automatically. For this, the order type-dependent parameters must be set up accordingly in Customizing. The CO object enables different cost itemizations for the process order. Within the order, there are lists for the following terms: Itemization (detailed overview of the individual costing items)

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Analysis (overview based on cost elements (material costs, production costs, overhead costs, ...)) Cost component split (overview based on costing-based costs components)

Calculating Planned Costs (II)

Figure 39: Calculating Planned Costs (II)

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Lesson: Costing

Exercise 14: Costing Exercise Objectives After completing this exercise, you will be able to: • Explain the determination of planned costs during process order creation

Business Example You will analyze the planned costs for a process order.

Task: Display one of the process orders you created for material T-FI1##. 1.

Display one of the process orders you created for material T-FI1##.

2.

Display the costs that the system determined when you created the order in the cost analysis. Describe how the system determined the above planned costs.

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How did the system determine the debits with regard to the planned material components (→ Goods Issues)?

4.

How did the system determine the debits with regard to the planned resource activities (→ Confirmations)?

5.

How did the system determine the credits with regard to the planned production quantity (→ Goods Receipt)?


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Solution 14: Costing Task: Display one of the process orders you created for material T-FI1##. 1.

Display one of the process orders you created for material T-FI1##. a)

(…) Process Order → Display Process order:

2.

Order number

Display the costs that the system determined when you created the order in the cost analysis. Describe how the system determined the above planned costs. a)

Choose Enter. The Display Process Order: Header – General Data screen appears. Choose Goto → Costs → Analysis

3.

How did the system determine the debits with regard to the planned material components (→ Goods Issues)? a)

The system uses the prices maintained in the material master records to determine the debits with regard to the planned material components ( → Goods Issues). See also the pages “Calculating Planned Costs (I) and (II)” in your participant handbook.

4.

How did the system determine the debits with regard to the planned resource activities (→ Confirmations)? a)

The system uses the tariffs defined for the activity types and cost centers of the resources to determine the debits with regard to the planned resource activities (→ Confirmations). See also the pages “Calculating Planned Costs (I) and (II)” in your participant handbook.

5.

How did the system determine the credits with regard to the planned production quantity (→ Goods Receipt)? a)

166

The system uses the price maintained in the material master record of the product to determine the credits with regard to the planned production quantity ( → Goods Receipt).


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Lesson: Costing

Exercise 15: Mass Processing Exercise Objectives After completing this exercise, you will be able to: • Perform scheduling in mass processing, and create and calculate capacity requirements

Business Example You will get an overview of how Scheduling, Capacity requirements creation and Costing can be carried out for several process orders in mass processing.

Task: 1.

Access the mass processing function for process orders. Note that here you can trigger the Scheduling, Capacity requirements creation and Costing functions previously explained for several process orders simultaneously.

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Solution 15: Mass Processing Task: 1.

Access the mass processing function for process orders. Note that here you can trigger the Scheduling, Capacity requirements creation and Costing functions previously explained for several process orders simultaneously. a)

168

(…) Process Order → Tools → Mass Processing


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Lesson: Costing

Lesson Summary You should now be able to: • Determine the planned costs for a process order.

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Unit Summary

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Unit Summary You should now be able to: • Use the different options for creating a process order • Explain the activities involved in process order creation • Define order types and order type-dependent parameters in Customizing • Make the appropriate Customizing settings for master data selection • Make the appropriate material master settings for selection using a production version • Explain the selection using a production version in manual process order creation and planned order conversion • Use the production version selection based on a quota arrangement • Select production versions manually • Read production versions • Include master recipes • Perform the following Customizing activities for scheduling process orders: define scheduling types, set scheduling parameters, define scheduling margins • Trace the scheduling of process orders in detail • Determine the planned costs for a process order.

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Test Your Knowledge

Test Your Knowledge

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1.

Name the basic activities of order creation.

2.

What information is defined in a production version?

3.

Which dates are determined within an order scheduling?

4.

Name the key cost components of the order


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Answers 1.

Name the basic activities of order creation. Answer: • • • • • •

2.

Order type determination Definition of order quantity and dates Production version determination Scheduling Capacity requirements determination Planned costs calculation

What information is defined in a production version? Answer: A production version determines which alternative BOM is used in combination with which master recipe for production.

3.

Which dates are determined within an order scheduling? Answer: •

Order dates – –

• • 4.

Start and finish dates Scheduled start and finish dates (production dates)

Operation and phase dates Dates for material staging process

Name the key cost components of the order Answer: • • • •

172

Production costs Material costs Overhead costs Process costs


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Unit 4 Process Planning and Order Release Unit Overview Topics: • • • • •

Material availability check Batch determination Batch determination and material quantity calculation Resource reservation (capacity requirements planning) Order release

Unit Objectives After completing this unit, you will be able to: • • • • • • • •

• • • • • •

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List the range of activities in process planning. Name the Customizing settings required for material availability checks Explain the functions of the material availability check and carry them out in the system Explain the Customizing settings for batch determination Create a batch search strategy Make the appropriate settings for batch determination in the material master records of your material components Carry out batch determination for your process order Carry out a sample scenario on how to use the functions of batch determination, active ingredient management, and material quantity calculation together. Name the different options for making resource reservations Describe the basics and the general process of resource reservation (capacity requirements planning) Dispatch operations in the capacity planning table of the ECC system Perform system-aided resource selection in the ECC System Release a process order Explain the order release function


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• •

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Explain the definition and application of a production scheduling profile Describbe the function of system and user statuses

Unit Contents Lesson: Process Planning .....................................................175 Lesson: Material Availability Check ..........................................177 Exercise 16: Material Availability Check: Customizing Settings .....181 Exercise 17: Material Availability Check: Applying in Process Orders ........................................................................191 Lesson: Batch Determination .................................................218 Exercise 18: Batch Determination: Overview...........................223 Exercise 19: Batch Determination: Customizing Settings ............227 Exercise 20: Batch Determination: Batch Search Strategy...........241 Exercise 21: Batch Determination: Applying in Process Orders .....247 Exercise 22: Batch Determination: Batch Entry Scenarios ...........261 Lesson: Batch Determination and Material Quantity Calculation .........270 Exercise 23: Batch Determination and Material Quantity Calculation...................................................................279 Lesson: Resource Reservation ...............................................292 Exercise 24: Resource Reservation: Overview ........................297 Exercise 25: Resource Reservation Using the Capacity Planning Table in the ECC System .........................................................301 Lesson: Order Release ........................................................319 Exercise 26: Statuses and Business Transactions ....................323 Exercise 27: Production Scheduling Profile.............................329 Exercise 28: System Statuses and User Statuses.....................337

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Lesson: Process Planning

Lesson: Process Planning Lesson Overview This lesson provides you with an overview of the range of activities in process planning.


List the range of activities in process planning.

Business Example Between creating and releasing the order, you can perform different planning activities with reference to process orders. You will get an overview of these possible steps in process planning.

Process Planning

Figure 40: Process Planning

Process planning comprises all activities that are performed during the time between creation and release of a process order.

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Lesson Summary You should now be able to: • List the range of activities in process planning.

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Lesson: Material Availability Check

Lesson: Material Availability Check Lesson Overview This lesson familiarizes you with the functions and settings of the material availability check for process orders.


Name the Customizing settings required for material availability checks Explain the functions of the material availability check and carry them out in the system

Business Example You will get an overview of the Customizing settings required for material availability checks for process orders. Afterwards, you will test the functions of the material availability check in the application.

Material Availability Check

Figure 41: Material Availability Check

Availability checks for material components ensure that only those orders are released for which the required material quantity is available on the calculated requirements date.

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The availability check can be triggered automatically or manually. In Customizing, you specify for each order type and plant whether an automatic availability check is to be carried out. Furthermore, you define whether the availability is to be checked during order creation and/or order release. A manual check can be carried out any time. You can either check the availability in a collective check for all components (automatically or manually), or in a separate check for each component (only manually). All receipt and issue elements to be considered are checked dynamically according to the ATP method (Available-to-Promise). Material quantities (including partial quantities) that are available at the requirements date are confirmed in the order. If the total required quantity of a material component is not available at the required date, the system sets the order status 'Material shortage'. In Customizing, you can specify that orders with a material shortage are locked and cannot be released. You can display missing parts for the order in the missing parts overview. The results of the availability check are recorded in the availability log. Availability checks are carried out according to checking rules that are defined in Customizing with reference to a material or application. The scope of the availability check is specified for each material and order type.

ATP Method: Example

Figure 42: ATP Method: Example

All the relevant receipt and issue elements are checked dynamically.

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The check is performed according to the ATP method (Available-to-Promise). Material quantities that are available at the requirements date are confirmed in the order. Check period: The check can be performed along the entire time axis but can also be restricted to the total replenishment lead time (material master). The MRP controller can use the ATP quantities to determine whether the master production schedule covers all issues and which part of the warehouse stock or production schedule is still available for new issues. The graphic illustrates the following scenario: It shows the planned material receipts and issues for material XYZ . The system carries out availability checks 1 to 4 for the existing reservations. In the third check, a material shortage is detected as the planned material receipts do not cover the requirements quantity. Due to the ATP logic (Available-to-Promise), the fourth check also detects that the material is not available although the material stock available at the requirements date would cover the requirement. However, the material stock was promised to the other reservations by checks 1 to 3.

Availability Check: Customizing

Figure 43: Availability Check: Customizing

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The following elements control the material availability check: • • •

•

180

You assign a checking group to each material in the material master. It groups together materials that are checked according to the same criteria. You define a checking rule for each application (for example, process order management, material requirements planning, sales and distribution,...). In check control, you define for each order type and plant whether the material availability is to be checked, how, and using which checking rule, and whether availability is to be checked when an order is created or released. The checking rule and checking group together define the scope of the availability check. The scope of check defines, for example, which MRP elements and stock categories are taken into account in the check.


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Exercise 16: Material Availability Check: Customizing Settings Exercise Objectives After completing this exercise, you will be able to: • Create checking rules • Define checking controls • Display checking groups • Set up the scopes of availability checks

Business Example You will make Customizing settings for the material availability check.

Task 1: 1.

Which elements control material availability checks for process orders? What do the individual elements mean and how do they depend on each other? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

Task 2: 1.

Define checking rule ## Checking rule, grp ## in Customizing for the availability check. If a checking rule has already been created for your group, use this one.


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Task 3: Define the check control for your order type PO## in plant 1100 in Customizing for the availability check as described in the following paragraphs. Note:The process order does not support production resources/tools. Therefore, set the No check indicator for the PRT availability. Set this indicator for capacity availability, too, as we will only look at material availability in this unit. 1.

Define Check availability during order creation. Specify that you do not want the system to automatically check material availability during order creation. Define that you do not want the system to automatically check material availability when the order is saved. Specify that checking rule ## is to be used during a material availability check for order creation. An ATP check is to be performed. Use the field help (F1) and the possible entries help (F4) to display information on creation control for collective conversion. Save your settings.

2.

Define Check availability during order release. Specify that you want the system to automatically check material availability during order release. The check is not to be restricted to a query of the Material shortage status. Define that you want the system to automatically check material availability when the order is saved. Specify that checking rule ## is to be used during a material availability check for a released order. An ATP check is to be performed. Specify that the user can decide whether an order will be released if material components are missing. Save your settings.

Task 4: 1.

To which checking group have your material components T-RTA## and T-RTB## been assigned? Continued on next page

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The assignment is made in the material master (on the MRP 3 view, in the Availability check field). Availability Check: ________________________________________

Task 5: Now define the scope of the check for checking group CH and checking rule ## in Customizing for the availability check. 1.

Now define the scope of the check for checking group CH and checking rule ## in Customizing for the availability check.

2.

To do so, copy the scope of check defined for checking group CH and checking rule PP. If a scope of check has already been created for checking group CH and checking rule ##, delete it and create it again.

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3.

Get an overview of the indicators that have been set and the settings you can make for your scope of check.

4.

Now define the scope of check for checking group 01 and checking rule ## by copying the scope of check for checking group 01 and checking rule PP.


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Solution 16: Material Availability Check: Customizing Settings Task 1: 1.

Which elements control material availability checks for process orders? What do the individual elements mean and how do they depend on each other? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

For information on the elements that control material availability checks for process orders, see the page “Availability Check: Customizing” in your participant handbook.

Task 2: 1.

Define checking rule ## Checking rule, grp ## in Customizing for the availability check. If a checking rule has already been created for your group, use this one. a)

Customizing: Production Planning for Process Industries → Process Order → Operations → Availability Check → Define Checking Rule Choose New Entries. ChR:

##

Description of checking rule:

Checking rule grp ##

Save your checking rule.


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Task 3: Define the check control for your order type PO## in plant 1100 in Customizing for the availability check as described in the following paragraphs. Note:The process order does not support production resources/tools. Therefore, set the No check indicator for the PRT availability. Set this indicator for capacity availability, too, as we will only look at material availability in this unit. 1.

Define Check availability during order creation. Specify that you do not want the system to automatically check material availability during order creation. Define that you do not want the system to automatically check material availability when the order is saved. Specify that checking rule ## is to be used during a material availability check for order creation. An ATP check is to be performed. Use the field help (F1) and the possible entries help (F4) to display information on creation control for collective conversion.


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Save your settings. a)

Customizing: (…) → Availability Check → Define Checking Control Choose New Entries. Plant:

1100

Order Type:

PO##

Availability Check:

1 Check availability during order creation

Material availability: X

No check

_

Check material availability when saving order

Checking Rule

##


Component Check Type

__

ATP check

PRT availability: X

No check

Capacity availability: X

No check

Save your settings. 2.

Define Check availability during order release. Specify that you want the system to automatically check material availability during order release. The check is not to be restricted to a query of the Material shortage status. Define that you want the system to automatically check material availability when the order is saved. Specify that checking rule ## is to be used during a material availability check for a released order. An ATP check is to be performed. Specify that the user can decide whether an order will be released if material components are missing. Continued on next page

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Save your settings. a)

Choose New Entries. Plant:

1100

Order Type:

PO##

Availability Check:

2 Check availability during order release

Material availability: _

No check

_

Status check

X

Check material availability when saving order

Checking Rule

##


Component Check Type

__

ATP check

Release material

1

User decides on release if parts are missing

PRT availability: X

No check

Capacity availability: X

No check

Save your settings.

Task 4: 1.

To which checking group have your material components T-RTA## and T-RTB## been assigned? The assignment is made in the material master (on the MRP 3 view, in the Availability check field).


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Availability Check: ________________________________________ a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-RTA## or T-RTB## Enter Go to the MRP 3 view. Enter Go to plant 1100. Enter Availability Check: CH Batches The checking groups are defined under Customizing: (…) → Availability Check → Define Checking Group

Task 5: Now define the scope of the check for checking group CH and checking rule ## in Customizing for the availability check. 1.

Now define the scope of the check for checking group CH and checking rule ## in Customizing for the availability check. a)

2.

Customizing: (…) → Availability Check → Define Scope of Check

To do so, copy the scope of check defined for checking group CH and checking rule PP.


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If a scope of check has already been created for checking group CH and checking rule ##, delete it and create it again. a)

The “Change View "Availability Check Control": Overview” screen appears. Select the entry for the checking group (Av) CH and for the checking rule (ChR) PP. Choose the Copy As ... icon. The “Change View "Availability Check Control": Details of Selected Set” screen appears. Overwrite checking rule PP with your own checking rule ##. Choose Enter. The system issues a warning about the name space you have used. Choose Enter again. The system now copies the scope of check for your checking rule. Save the scope of check you have created. Hint: If a scope of check has already been created for checking group CH and checking rule ##, delete it and create it again.

3.

Get an overview of the indicators that have been set and the settings you can make for your scope of check. a)

4.


Now define the scope of check for checking group 01 and checking rule ## by copying the scope of check for checking group 01 and checking rule PP. a)

Select the entry for checking group (Av) 01 and for checking rule (ChR) PP. Choose the Copy as ... icon. The “Change View "Availability Check Control": Details of Selected Set” screen appears. Overwrite checking rule PP with your own checking rule ##. Choose Enter. The system issues a warning about the name space you have used. Choose Enter again. The system now copies the scope of check for your checking rule. Save the scope of check you have created. Hint: If a scope of check has already been created for checking group 01 and checking rule ##, delete it and create it again.

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Exercise 17: Material Availability Check: Applying in Process Orders Exercise Objectives After completing this exercise, you will be able to: • Use the automatic check during order release • Trigger a manual check • Explain the ATP checking procedure • Evaluate missing parts

Business Example You will test the different options and functions for carrying out a material availability check in a sample scenario.

Task 1: 1.

Create a process order of order type PO## for material T-HTB1## in plant 1100. Order quantity:

500,000 g

Start:

Today + 2 months

Enter

Task 2: Create another process order of order type PO## for your material T-HTB1## in plant 1100. Enter 600 000 g as the quantity to be produced. Enter Today +4 weeks as the basic start date. 1.

Create another process order of order type PO## for your material T-HTB1## in plant 1100. Enter 600 000 g as the quantity to be produced. Enter Today + 4 weeks as the basic start date.

2.

Display the stock/requirements list for material T-HTB1##. Write down the data displayed in the list in the following table:


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Date

3.

MRP element

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MRP element data

Rec./reqd. qty

Available qty

Display the stock/requirements lists for your materials T-RTA## and T-RTB##. Write down the data displayed in these lists in the following tables: T-RTA## Date

MRP element

MRP element data

Rec./reqd. qty

Available qty

MRP element

MRP element data

Rec./reqd. qty

Available qty

T-RTB## Date

Task 3: Display the stock/requirements list for material T-HTB1## again. 1.

From the list, go into the process order that is chronologically first in the change mode.

2.

Go to the material list of the process order and display the general data on the assigned material components T-RTA## and T-RTB##. Write down the following:


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T-RTA##

T-RTB##

Requirement quantity Confirmed qty Have quantities been committed for the components by an availability check? ______________________________________________________ 3.

Why did the system not check material availability when you created the order? Which settings would you have to make to specify that an automatic availability check is carried out during order creation? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

4.

Release the order. Then display the general data for components T-RTA## and T-RTB## again. What do you notice? ______________________________________________________ ______________________________________________________ ______________________________________________________ Write down the following: T-RTA##

T-RTB##

Requirement quantity Confirmed qty 5.

Why did the system check material availability when you released the order? ______________________________________________________ ______________________________________________________

6.

Which new order status was set with regard to the material availability check? ______________________________________________________

7.

Check the material availability for component T-RTA## individually. Display the ATP quantities. Continued on next page

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Write down the following: Date

MRP element

MRP element data

Rec./reqd. Conqty firmed

Available qty

STOCK SimReq

Simulated requirements

OrdRes

Totals record

Now display the scope of check. Save your order.

Task 4: You are back in the stock/requirements list for material T-HTB1##. 1.

From the list, enter the other process order that comes later in time in the change mode.

2.

Do not release this order. In this scenario, manually check the material availability of all material components in the order.

3.

Check whether the availability check was carried out successfully by displaying the order status and the general data on the material components.

4.

Check the material availability for component T-RTA## individually. Display the ATP quantities. Write down the following:


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Date

MRP element

MRP element data


Available qty

STOCK SimReq

Totals record

OrdRes


How would you interpret the result? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ Save the order.

Task 5: 1.

Display the stock overview of your material component T-RTA## in inventory management.

2.

Write down the following information about the stock situation: Unrestricted use

Reserved

Plant 1100 Warehouse 0002 Batch RA3050 3.

Post a goods issue for batch RA3050 of material T-RTA##. Withdraw 1,300 l from plant 1100, storage location 0002. Use movement type 201 and debit cost center 4258 for this.

4.

Display the stock overview for material T-RTA## again. Write down the following:


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Unrestricted use

Reserved

Plant 1100 Storage location 0002 Batch RA3050

Task 6: 1.

Create another process order of order type PO## for material T-HTB1## in plant 1100. Enter 400,000 g as the quantity to be produced. Enter today's date as the basic start date.

2.

Display the stock/requirements list for material T-HTB1##. Write down the data displayed in the list in the following table: Date

MRP element

MRP element data

Rec./reqd. qty

Available qty

3.

From the list, go into the process order you have just created in the change mode.

4.

Manually check the material availability of the material components in a collective check. Which message does the system issue? ______________________________________________________ ______________________________________________________

5.

Go to the Material shortfall overview. Which information is displayed here? ______________________________________________________ ______________________________________________________ Write down the following: Requirement quantity: _________________________________________ Continued on next page

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Confirmed quantity: _____________________________________ 6.

Which new order status was set with regard to the missing material availability? _____________________________________________________

7.

Display the general data on material components T-RTA## and T-RTB##. Write down the following: T-RTA##

T-RTB##

Requirement quantity Confirmed qty 8.

Check the material availability for component T-RTA## individually. Display the ATP quantities. Write down the following: Date

MRP element

MRP element data


Cum. ATP qty

STOCK SimReq Simulated requirements OrdRes

Totals record

OrdRes

Totals record

How would you interpret the result? ______________________________________________________ ______________________________________________________ ______________________________________________________ 9.

Try to release the order. Which message does the system issue? ______________________________________________________ ______________________________________________________ Which setting determines the fact that the material availability for the order is automatically checked during order release? Continued on next page

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______________________________________________________ ______________________________________________________ Which settings determine that users can decide whether they want to release the order despite the material shortage? ______________________________________________________ ______________________________________________________ Do not release the order. Save the order.

Task 7: Missing parts information system: 1.

You can use the missing parts information system to analyze material shortage situations. Choose (...) → Process Order → Reporting → Missing Parts Info System Hint: From the missing parts info system, you can navigate directly to backorder processing.

Task 8: Backorder processing: 1.

Enter backorder processing for material T-RTA##. Choose checking rule ##.

2.

Change the committed quantity for the reservation that is furthest away in the future from 250 L to 200 L.

3.

Change the committed quantity for the earliest reservation from 150 L to 200 L.

4.

Save the data in backorder processing. Note: After changing the confirmation, the order status MACM that may have been set is removed.

Task 9: Collective availability check in mass processing: 1.

Go into the mass processing for process orders. Choose the order headers list and the standard layout. Continued on next page

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In the selection tab page, choose the production plant 1100 and the MRP controller S##. In the mass processing tab page, choose the function material availability check. The function is to be executed immediately. Set the function parameters so that the availability data is reset and that an ATP check for all materials is specified in the scope of processing. Now execute the function. 2.

According to your selection criteria, the system displays a list with your three orders for material T-HTB1##. Trigger the mass processing for all three orders at the same time.

3.

Analyze your three process orders from the list with regard to the committed quantities for the individual components from the list of the order information system. Compare the result to your backorder processing in exercise 8.

Task 10: ATP quantity overview 1.

To get an ATP quantity overview for a material (for example, T-RTA##), choose Logistics → Production → Production Control → Control → Availability Overview

Task 11: Reset the availability data in the order 1.

You can reset the availability data in an order using Process Order → Functions → Availability check → Reset material

Task 12: 1.

For the following exercises, cancel the material document you posted for the goods issue of material T-RTA## in exercise 5-3. To check whether the material document was canceled successfully, display the stock overview for the material.

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Solution 17: Material Availability Check: Applying in Process Orders Task 1: 1.

Create a process order of order type PO## for material T-HTB1## in plant 1100. Order quantity:

500,000 g

Start:

Today + 2 months

Enter a)

See description in the exercise

Task 2: Create another process order of order type PO## for your material T-HTB1## in plant 1100. Enter 600 000 g as the quantity to be produced. Enter Today +4 weeks as the basic start date. 1.

Create another process order of order type PO## for your material T-HTB1## in plant 1100. Enter 600 000 g as the quantity to be produced. Enter Today + 4 weeks as the basic start date. a)

(...) → Process Order → Create → With Material Material no.:

T-HTB1##

Plant:

1100

Process order type:

PO##

Enter Total qty:

600,000 G

Start:

Today + 4 weeks

Enter Save your order. Continued on next page

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2.

Display the stock/requirements list for material T-HTB1##. Write down the data displayed in the list in the following table: Date

a)

MRP element

MRP element data

Rec./reqd. qty

Available qty

(…) → Process Order → Environment → Stock/Requirements List Material:

T-HTB1##

Plant:

1100

Enter

3.

Date

MRP element

MRP element data

Rec./reqd. qty

Available qty

Today

STOCK

Reqmts date

PR-ORD

Order number /PO##

600 000

600 000

Reqmts date

PR-ORD

Order number /PO##

500 000

1 100 000

0

Display the stock/requirements lists for your materials T-RTA## and T-RTB##. Write down the data displayed in these lists in the following tables:


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T-RTA## Date

MRP element

MRP element data

Rec./reqd. qty

Available qty

MRP element

MRP element data

Rec./reqd. qty

Available qty

T-RTB## Date

a) T-RTA## Date

MRP element

MRP element data

Rec./reqd. qty

Available qty

Today

STOCK

Reqmts date

OrdRes

T-HTB1##

300 -

1 700

Reqmts date

OrdRes

T-HTB1##

250 -

1 450

Date

MRP element

MRP element data

Rec./reqd. qty

Available qty

Today

STOCK

Reqmts date

OrdRes

T-HTB1##

300 -

1 750

Reqmts date

OrdRes

T-HTB1##

250 -

1 450

2 000

T-RTB##

2 000


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Task 3: Display the stock/requirements list for material T-HTB1## again. 1.

From the list, go into the process order that is chronologically first in the change mode. a)

2.

Position the cursor on the MRP element of the process order that is chronologically first and choose the Change element icon.

Go to the material list of the process order and display the general data on the assigned material components T-RTA## and T-RTB##. Write down the following: T-RTA##

T-RTB##

Requirement quantity Confirmed qty Have quantities been committed for the components by an availability check? ______________________________________________________ a)

Choose Materials. T-RTA##

T-RTB##

Requirement quantity

300 l

300 kg

Confirmed qty

0

0

No quantities have been committed by an availability check. 3.

Why did the system not check material availability when you created the order? Which settings would you have to make to specify that an automatic availability check is carried out during order creation? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

Solution: See the exercise “Material availability check: Customizing settings”, exercise 3-2


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Release the order. Then display the general data for components T-RTA## and T-RTB## again. What do you notice? ______________________________________________________ ______________________________________________________ ______________________________________________________ Write down the following: T-RTA##

T-RTB##

Requirement quantity Confirmed qty a)

Choose the Release icon in the order. During order release, the system automatically checked the availability of the material components. The requirements quantities were committed.

5.

T-RTA##

T-RTB##


300 l

300 kg

Confirmed qty

300 l

300 kg

Why did the system check material availability when you released the order? ______________________________________________________ ______________________________________________________ a)

6.

Solution: See the exercise “Material availability check: Customizing settings”, exercise 3-3

Which new order status was set with regard to the material availability check? ______________________________________________________ a)

Go to the order header. MACM Material committed

7.

Check the material availability for component T-RTA## individually. Display the ATP quantities. Write down the following: Continued on next page

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Date

MRP element

MRP element data


Available qty

STOCK SimReq


OrdRes

Totals record

Now display the scope of check. Save your order. a)

In the material list, select the line for component T-RTA## and choose Material → Check availability. The Confirmation Proposal screen appears. Choose ATP quantities. Date

MRP element

Today

STOCK

Reqmts date

SimReq

Reqmts date

OrdRes

MRP element data


Available qty

2 000

2 000


300 -

2 000

Totals record

250 -

0

2 000

Choose Scope of check. Go back to the material list and save your order.

Task 4: You are back in the stock/requirements list for material T-HTB1##. 1.

From the list, enter the other process order that comes later in time in the change mode. a)

Position the cursor on the MRP element of the process order that is chronologically last and choose the Change Element icon. Continued on next page

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Do not release this order. In this scenario, manually check the material availability of all material components in the order. a)

3.

Check whether the availability check was carried out successfully by displaying the order status and the general data on the material components. a)

4.

Choose Material (Material availability check - ATP) in the order.


Check the material availability for component T-RTA## individually. Display the ATP quantities. Write down the following: Date

MRP element

MRP element data


Available qty

STOCK SimReq

Totals record

OrdRes


How would you interpret the result? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________


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Save the order. a)

In the material list, select the line for component T-RTA## and choose Material → Check availability. The Confirmation Proposal screen appears. Choose ATP quantities. Date

MRP element

MRP element data


Available qty

Today

STOCK

2 000

1 700

Reqmts date

SimReq

Totals record

300 -

Reqmts date

OrdRes


250 -

300

1 700 1 700

During the availability check of the process order that is chronologically first, the system confirmed 300 L of component T-RTA## to this order. For this reason, an ATP quantity (available-to-promise quantity) of only 1,700 L out of the 2,000 L of the present material stock is available for the current order. Go back to the material list and save the order.

Task 5: 1.

Display the stock overview of your material component T-RTA## in inventory management. a)

Logistics → Materials Management → Inventory Management → Environment → Stock → Stock Overview Material:

T-RTA##

Plant:

1100

Execute icon 2.

Write down the following information about the stock situation:


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Unrestricted use

Reserved

Plant 1100 Warehouse 0002 Batch RA3050 a)

3.

Unrestricted use

Reserved

Plant 1100

2 000

550

Storage location 0002

2 000

550

Batch RA3050

2 000

0

Post a goods issue for batch RA3050 of material T-RTA##. Withdraw 1,300 l from plant 1100, storage location 0002. Use movement type 201 and debit cost center 4258 for this. a)

(…) → Inventory Management → Goods Movement → Goods Issue Movement type:

201

Plant:

1100

Storage location:

0002

Choose Enter. The Enter Goods Issue: New Items screen appears. Cost Center:

4258

Material:

T-RTA##

Quantity:

1300

Batch:

RA3050

Save the goods issue. 4.

Display the stock overview for material T-RTA## again. Write down the following:


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Unrestricted use

Reserved

Plant 1100 Storage location 0002 Batch RA3050 a)

(…) → Inventory Management → Environment → Stock → Stock Overview Unrestricted use

Reserved

Plant 1100

700

550

Storage location 0002

700

550

Batch RA3050

700

0

Task 6: 1.

Create another process order of order type PO## for material T-HTB1## in plant 1100. Enter 400,000 g as the quantity to be produced. Enter today's date as the basic start date. a)

(...) → Process Order → Create → With Material Material number:

T-HTB1##

Plant:

1100

Process order type:

PO##

Enter Total qty:

400,000 G

Start:

Today

Enter Save your order. 2.

Display the stock/requirements list for material T-HTB1##. Write down the data displayed in the list in the following table:


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Date

a)

3.

MRP element data

Rec./reqd. qty

Available qty

(…) → Process Order → Environment → Stock/Requirements List Date

MRP MRP element element data

Today

STOCK

Rec./reqd. qty

Available qty 0

Reqmts PR-ORD Order number date /PO##

400 000

400 000

Reqmts PR-ORD Order number date /PO##/FR

600 000

1 000 000

Reqmts PR-ORD Order number date /PO##

500 000

1 500 000

From the list, go into the process order you have just created in the change mode. a)

4.

MRP element

SCM340

Position the cursor on the MRP element of the new process order and choose the Change element icon.

Manually check the material availability of the material components in a collective check. Which message does the system issue? ______________________________________________________ ______________________________________________________ a)

Choose Material (Material availability check - ATP) in the order. The system issues the message Material shortage for order.

5.

Go to the Material shortfall overview. Which information is displayed here? ______________________________________________________ ______________________________________________________ Write down the following: Continued on next page

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Requirement quantity: _________________________________________ Confirmed quantity: _____________________________________ a)

Choose Material shortfall overvi For the current process order, the requirements quantity for material component T-RTA## amounts to 200 L. However, only 150 L can be confirmed.

6.

Requirement quantity:

200

Confirmed qty:

150

Which new order status was set with regard to the missing material availability? _____________________________________________________ a)

7.

MSPT Material shortage

Display the general data on material components T-RTA## and T-RTB##. Write down the following: T-RTA##

T-RTB##

Requirement quantity Confirmed qty a)

8.

T-RTA##

T-RTB##


200 L

200 kg

Confirmed qty

150 L

200 kg

Check the material availability for component T-RTA## individually. Display the ATP quantities. Write down the following:


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Date

MRP element

SCM340

MRP element data


Cum. ATP qty

STOCK SimReq Simulated requirements OrdRes

Totals record

OrdRes

Totals record

How would you interpret the result? ______________________________________________________ ______________________________________________________ ______________________________________________________ a) Date

MRP element

MRP element data

Rec./reqd.Conqty firmed

Cum. ATP qty

Today STOCK

700

150

Reqmts date

SimReq Simulated requirements

200 -

0

150

Reqmts date

OrdRes

Totals record

300 -

300

150

Reqmts date

OrdRes

Totals record

250 -

250

150

For the current order, an ATP quantity of 150 L is available for component T-RTA##. Due to the ATP logic, the system cannot cover the requirements quantity of 200 L although 700 L would be available on the requirements date. The reason for this is that 550 L of component T-RTA## have already been promised to later process orders in availability checks carried out before. 9.

Try to release the order. Which message does the system issue? Continued on next page

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______________________________________________________ ______________________________________________________ Which setting determines the fact that the material availability for the order is automatically checked during order release? ______________________________________________________ ______________________________________________________ Which settings determine that users can decide whether they want to release the order despite the material shortage? ______________________________________________________ ______________________________________________________ Do not release the order. Save the order. a)

When you try to release the order, the system tells you that there is a Material shortage. Due to the Customizing settings for the checking control that you have made in the exercise “Material availability check: Customizing settings”, exercise 3-3, the material availability is automatically checked during order release. In the checking control settings, you also specified that the user decides whether an order will be released in case of a material shortage. Do not release the order. Choose Cancel. Save the order.

Task 7: Missing parts information system: 1.

You can use the missing parts information system to analyze material shortage situations. Choose (...) → Process Order → Reporting → Missing Parts Info System Hint: From the missing parts info system, you can navigate directly to backorder processing. a)

See exercise


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Task 8: Backorder processing: 1.

Enter backorder processing for material T-RTA##. Choose checking rule ##. a)

(…) → Process Order → Reporting → Backorder Processing → Material Material:

T-RTA##

Plant:

1100

MRP area:

1100

Checking Rule:

##

Enter The Backorder Processing: Overview screen appears. 2.

Change the committed quantity for the reservation that is furthest away in the future from 250 L to 200 L. a)

Select the line for the reservation that is furthest away in the future and choose Change confirmation. Committed:

200

Choose Edit → Copy or the relevant function key. 3.

Change the committed quantity for the earliest reservation from 150 L to 200 L. a)

Select the line of the reservation that comes first in time and choose Change confirmation. Committed:

200

Choose Edit → Copy or the relevant function key. 4.

Save the data in backorder processing. Note: After changing the confirmation, the order status MACM that may have been set is removed. a)



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Task 9: Collective availability check in mass processing: 1.

Go into the mass processing for process orders. Choose the order headers list and the standard layout. In the selection tab page, choose the production plant 1100 and the MRP controller S##. In the mass processing tab page, choose the function material availability check. The function is to be executed immediately. Set the function parameters so that the availability data is reset and that an ATP check for all materials is specified in the scope of processing. Now execute the function. a)

2.

(…) → Process Order → Tools → Mass Processing

According to your selection criteria, the system displays a list with your three orders for material T-HTB1##. Trigger the mass processing for all three orders at the same time. a)

3.


Analyze your three process orders from the list with regard to the committed quantities for the individual components from the list of the order information system. Compare the result to your backorder processing in exercise 8. a)

To navigate to an order from within the list, choose Change order or Display order.

Task 10: ATP quantity overview 1.

To get an ATP quantity overview for a material (for example, T-RTA##), choose Logistics → Production → Production Control → Control → Availability Overview a)

See exercise

Task 11: Reset the availability data in the order 1.

You can reset the availability data in an order using Process Order → Functions → Availability check → Reset material Continued on next page

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a)

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See exercise

Task 12: 1.

For the following exercises, cancel the material document you posted for the goods issue of material T-RTA## in exercise 5-3. To check whether the material document was canceled successfully, display the stock overview for the material. a)

(…) → Inventory Management → Material Document → Cancel/Reverse Use matchcode search (F4 for the Material doc. field) to search for the desired material document: Material:

T-RTA##

Movement type:

201

Execute icon The system displays the material document. Double-click the line in the list. The system copies the document number in the Material doc. field. Choose Enter. The Cancel Material Document: Selection Screen appears. Save your cancellation. The system issues a warning in which it tells you that batch RA3050 has already been posted in stock. Choose Enter to confirm this warning.

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Lesson Summary You should now be able to: • Name the Customizing settings required for material availability checks • Explain the functions of the material availability check and carry them out in the system

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Lesson: Batch Determination Lesson Overview This lesson familiarizes you with the functions and settings of the batch determination for process orders.


Explain the Customizing settings for batch determination Create a batch search strategy Make the appropriate settings for batch determination in the material master records of your material components Carry out batch determination for your process order

Business Example You will get an overview of the Customizing settings required for batch determination for process orders. Afterwards, you will create a batch search strategy and test the batch determination function in different scenarios.

Batch Determination in the Process Order

Figure 44: Batch Determination in the Process Order

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Lesson: Batch Determination

You can use the batch determination function to assign batches required for production. The system looks for batches in stock according to user-defined selection criteria. You can define the selection conditions for batch determination as characteristic values in classes of class type Batch. You can assign this class either directly to the material component or to a search strategy. The characteristics of a batch are also defined by characteristic values. On the basis of the selection conditions and batch classification, the system selects suitable batches in stock. An availability check is carried out at batch level. The batch determination function is also available for the following applications: • • • • •

Production order Repetitive manufacturing Sales (sales order and delivery) Inventory management (goods movement) Warehouse management

Batch Determination: Search Strategy

Figure 45: Batch Determination: Search Strategy

The batch search strategy specifies the criteria according to which batches are selected in batch determination and the steps that are further taken with them. The batch search strategy is an application-specific master record.

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You create a batch search strategy with reference to a strategy type (= condition type) defined in Customizing.

Batch Determination: Customizing

Figure 46: Batch Determination: Customizing

Condition tables define the combination of fields representing the key of the batch search strategy. The access sequence specifies the sequence in which the system accesses condition tables during batch determination. A strategy type contains default values that are taken over when a batch search strategy is created. The following information can be stored: • • •

A selection class A sort rule Control parameters for batch split and the quantity proposal

The search procedure is the starting point for batch determination. Search procedures are assigned to application-specific keys (in process manufacturing, this is the process order) in a 1:1 relationship. A search procedure is assigned several strategy types. During batch determination, the system tries to find strategy records (= batch search strategies) for these strategy types.

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Batch Determination: Process

Figure 47: Batch Determination: Process

Settings in the Material Master Record

Figure 48: Settings in the Material Master Record

The 'Batch entry' indicator determines when batches have to be determined for the material components of orders.

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The indicator can have the following meanings: • • • •

222

The batches must only be determined when posting the goods issues. You do not need to enter a batch number in the process order. The batches must be entered in the order before the order is released. The batches must be entered in the order before the goods issue is posted, but not necessarily before the order is released. The batches are automatically determined when the order is released.


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Exercise 18: Batch Determination: Overview Exercise Objectives After completing this exercise, you will be able to: • Explain the elements controlling batch determination for process orders • Describe the general process of batch determination

Business Example You will get an overview of the elements available for controlling batch determination for process orders. You will outline the general process of batch determination.

Task: 1.

Which elements can you use to control batch determination for process orders? Outline the meaning of these elements and how they depend on each other. Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Continued on next page

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2.

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Outline the general process of batch determination for process orders. Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

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Solution 18: Batch Determination: Overview Task: 1.

Which elements can you use to control batch determination for process orders? Outline the meaning of these elements and how they depend on each other. Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

2.

For information on the elements that control batch determination, see the pages “Batch Determination in the Process Order”, “Batch Determination: Search Strategy”, and “Batch Determination: Customizing” in your participant handbook.

Outline the general process of batch determination for process orders. Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Continued on next page

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___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

226

For information on the batch determination process, see the page “Batch Determination: Process” in your participant handbook.


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Exercise 19: Batch Determination: Customizing Settings Exercise Objectives After completing this exercise, you will be able to: • Display condition tables • Maintain access sequences • Create strategy types • Create batch search procedures • Define sort rules

Business Example You will make the appropriate Customizing settings for batch determination for process orders.

Task 1: 1.

Once again, get an overview of the Customizing activities that must be carried out for setting up batch determination for process orders.

Task 2: Display condition tables 30 and 599 for batch determination in process orders in Customizing. 1.

Display condition tables 30 and 599 for batch determination in process orders in Customizing.

2.

Write down which fields have been selected from the field catalog for table 30 Order type/plant/component. _____________________________________________________ _____________________________________________________ _____________________________________________________

3.

Write down which fields have been selected from the field catalog for table 599 Order type/plant. _____________________________________________________ _____________________________________________________ _____________________________________________________ Continued on next page

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Task 3: Display the access sequences that have been defined for batch determination in process orders in Customizing. 1.

Display the access sequences that have been defined for batch determination in process orders in Customizing.

2.

Display the accesses for access sequence CO01 OrdType/plant/material. Write down in which sequence the system accesses which condition tables during batch determination. Access sequence CO01 Accesses AcNo

3.

Tab

Display the fields for the above tables. Write down the field descriptions of the fields which can be used as the key for a search strategy (see exercise 2). Access CO01 10 Table 30 Field name long

Access CO01 20 Table 599 Field name long

Task 4: In Customizing, define strategy type GR## Strategy type grp ## for batch determination in process orders as follows: 1.

Define the strategy type Grp. ##

2.

Enter access sequence CO01 for the strategy type.

3.

Do not yet define a selection class. Continued on next page

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4.

Do not yet define a sort sequence.

5.

Specify that a batch split of no more than 3 batches is allowed for the time being.

6.

Specify that the number of batch splits may be changed in the process order.

7.

Specify that an overdelivery is allowed in batch determination.

8.

Specify that the quantities are displayed in the material's stockkeeping unit during batch determination.

9.

Batch determination is to be carried out interactively. Save your strategy type.

Task 5: In Customizing, define batch search procedure ZZGR## Batch search procedure grp ## for batch determination in process orders. 1.

Define the batch search procedure.

2.

Define strategy type (= condition type) GR## as step 1 / counter 1 for batch search procedure control. Save your batch search procedure.

Task 6: 1.

Assign your batch search procedure ZZGR## to your process order type PO## in plant 1100 in Customizing. Set the Check batch indicator. Use the field help (F1) for information on the meaning of this indicator. Save your settings.

Task 7: Create a second session and display the classification data of the material master records for materials T-RTA## and T-RTB##. 1.

Display the classification data.

2.

To which classes of class type 023 Batch have the materials been assigned? Which characteristics have been assigned to these classes? To answer the second question, jump to the assigned class for the relevant material from the classification view. Continued on next page

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Class

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Description

Characteristic description

T-RTA## T-RTB##

Task 8: Create selection class SEGR## Selection class grp ## in Customizing. 1.

Create the selection class.

2.

Assign the characteristics N-001 Refractive index and N-002 Melting point to the selection class. Save the selection class.

Task 9: Create sort rule SOGR## Sort sequence grp ## in Customizing. 1.

Create sort rule SOGR## 'Sort sequence grp ##' in Customizing.

2.

Assign the above characteristics N-001 and N-002 to your sort sequence.

3.

Specify that during batch determination in the process order you want the system to sort the batches found for materials T-RTA## or T-RTB## in descending order of the values for characteristics N-001 or N-002. Save your sort rule.

Task 10: 1.

230

Assign your selection class SEGR## and sort sequence SOGR## to your strategy type GR##.


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Solution 19: Batch Determination: Customizing Settings Task 1: 1.

Once again, get an overview of the Customizing activities that must be carried out for setting up batch determination for process orders. a)

For information on the settings for batch determination for process orders, see the page “Batch determination: Customizing” in your participant handbook.

Task 2: Display condition tables 30 and 599 for batch determination in process orders in Customizing. 1.

Display condition tables 30 and 599 for batch determination in process orders in Customizing. a)

Customizing: Logistics - General → Batch Management → Batch Determination and Batch Check → Condition Tables → Define process order condition tables Choose Display batch determination condition table (process order).

2.

Write down which fields have been selected from the field catalog for table 30 Order type/plant/component. _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Table: 30 Enter Selected fields: Order type Plant Material Choose Back.

3.

Write down which fields have been selected from the field catalog for table 599 Order type/plant. Continued on next page

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_____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Table: 599 Enter Selected fields: Order type Plant

Task 3: Display the access sequences that have been defined for batch determination in process orders in Customizing. 1.

Display the access sequences that have been defined for batch determination in process orders in Customizing. a)

Customizing: (...) → Batch Determination and Batch Check → Assess Sequences → Define process order access sequences Choose Enter to confirm the information telling you that the table is client-independent.

2.

Display the accesses for access sequence CO01 OrdType/plant/material. Write down in which sequence the system accesses which condition tables during batch determination.


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Access sequence CO01 Accesses AcNo

a)

Tab

Select the line for access sequence CO01 and choose Accesses in the dialog structure. Access sequence CO01 Accesses

3.

AcNo

Tab

10

30 Order type/plant/component

20

599 Order type/plant

Display the fields for the above tables. Write down the field descriptions of the fields which can be used as the key for a search strategy (see exercise 2). Access CO01 10 Table 30 Field name long


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Access CO01 20 Table 599 Field name long a)

Select the line for the relevant table and choose Fields in the dialog structure. Access CO01 10 Table 30 Field name Order type long Plant Material Access CO01 20 Table 599 Field name Order type long Plant

Task 4: In Customizing, define strategy type GR## Strategy type grp ## for batch determination in process orders as follows: 1.

Define the strategy type Grp. ## a)

Customizing: (...) → Batch Determination and Batch Check → Strategy Types → Define Process Order Strategy Types Choose New Entries. Condition type:

2.

GR## Strategy type grp ##

Enter access sequence CO01 for the strategy type. a) Access sequence:

CO01


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3.

Do not yet define a selection class. a) Class:

4.

____ (no entry)

Do not yet define a sort sequence. a) Sort sequence:

5.

____ (no entry)

Specify that a batch split of no more than 3 batches is allowed for the time being. a) No. of splits:

6.

3

Specify that the number of batch splits may be changed in the process order. a) X

7.

Changes allowed

Specify that an overdelivery is allowed in batch determination. a) X

8.

OverDel allowed

Specify that the quantities are displayed in the material's stockkeeping unit during batch determination. a) Display UoM:

9.

A

Batch determination is to be carried out interactively.


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Save your strategy type. a) X

Dialog batch determin.

Save your strategy type.

Task 5: In Customizing, define batch search procedure ZZGR## Batch search procedure grp ## for batch determination in process orders. 1.

Define the batch search procedure. a)

Customizing: (...) → Batch Determination and Batch Check → Batch Search Procedure Definition → Define Process Order Search Procedure Choose New Entries.

2.

Procedure:

ZZGR##

Description:

Batch search procedure grp ##

Define strategy type (= condition type) GR## as step 1 / counter 1 for batch search procedure control. Save your batch search procedure. a)

Select the line for your search procedure and choose Control in the dialog structure. Choose New Entries. Level:

1

Cntr:

1

CTyp:

GR##

Save your batch search procedure.

Task 6: 1.

Assign your batch search procedure ZZGR## to your process order type PO## in plant 1100 in Customizing. Continued on next page

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Set the Check batch indicator. Use the field help (F1) for information on the meaning of this indicator. Save your settings. a)

Customizing: (…) → Batch Determination and Batch Check → Batch Search Procedure Allocation and Check Activation → Assign Search Procedures to Production and Activate Check → Assign Search Procedure to Process Order and Activate Check Make the following assignment: Plant:

1100

Type:

PO##

Search:

ZZGR##

Check batch:

X

Save your settings.

Task 7: Create a second session and display the classification data of the material master records for materials T-RTA## and T-RTB##. 1.

Display the classification data. a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material:

T-RTA## or T-RTB##

Enter Choose Classification. Enter 2.

To which classes of class type 023 Batch have the materials been assigned? Which characteristics have been assigned to these classes? To answer the second question, jump to the assigned class for the relevant material from the classification view.


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Description


T-RTA## T-RTB## a)

Choose class type 023 Batch. Select the line for the class and choose Environment → Display Master Data. To display the assigned characteristic, choose the Char. tab. Class

Description


T-RTA## N-001

N-001

Refractive index

T-RTB## N-002

N-002

Melting point

Task 8: Create selection class SEGR## Selection class grp ## in Customizing. 1.

Create the selection class. a)

Customizing: (...) → Batch Determination and Batch Check → Define Selection Classes Choose Create Selection Classes. Class:

SEGR##

Class type:

023

Enter Description: 2.

Selection class grp ##

Assign the characteristics N-001 Refractive index and N-002 Melting point to the selection class. Save the selection class. a)

See exercise


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Task 9: Create sort rule SOGR## Sort sequence grp ## in Customizing. 1.

Create sort rule SOGR## 'Sort sequence grp ##' in Customizing. a)

Customizing: (...) → Batch Determination and Batch Check → Create Selection Classes Choose Create Selection Classes. Sort sequence:

SOGR##

Enter Description: 2.

Sort sequence grp ##

Assign the above characteristics N-001 and N-002 to your sort sequence. a)

Choose characteristics. Description N-001 N-002

3.

Specify that during batch determination in the process order you want the system to sort the batches found for materials T-RTA## or T-RTB## in descending order of the values for characteristics N-001 or N-002. Save your sort rule. a) Description

Descending

N-001

X

N-002

X

Save your selection class.


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Task 10: 1.

Assign your selection class SEGR## and sort sequence SOGR## to your strategy type GR##. a)

Customizing: (...) → Batch Determination and Batch Check → Strategy Types → Define Process Order Strategy Types Double-click on Strategy type GR##. Enter selection class SEGR##. Enter sort sequence SOGR##. Save.

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Exercise 20: Batch Determination: Batch Search Strategy Exercise Objectives After completing this exercise, you will be able to: • Describe the function of a batch search strategy • Create a batch search strategy

Business Example You will create batch search strategies with reference to the strategy type you defined in Customizing.

Task 1: 1.

Outline the function of batch search strategies. Which prerequisite must be fulfilled to be able to create a batch search strategy? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: Create batch search strategies with reference to your strategy type GR##. 1.

Create batch search strategies with reference to your strategy type GR##.

2.

Select key combination Order type/plant/component.

3.

Create strategy records for your order type PO##, plant 1100, and your materials T-RTA## and T-RTB##.

4.

Display the detail data for both strategies and check whether the system has correctly copied the settings you made in Customizing for strategy type GR##.

5.

No selection class has been assigned to the components. Continued on next page

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Choose Selection criteria to adopt selection class SEGR## assigned to your strategy type GR## for each component. Assign the following values to the characteristics as selection criteria for batch determination: Material T-RTA## Characteristic description

Value

Refractive index

1,3895 – 1,3913

Melting point Material T-RTB## Characteristic description

Value

Refractive index Melting point 6.

155 - 165

No sort sequence has been assigned to the components. Choose Sort to adopt sort sequence SOGR## assigned to your strategy type GR## for each component.

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Solution 20: Batch Determination: Batch Search Strategy Task 1: 1.

Outline the function of batch search strategies. Which prerequisite must be fulfilled to be able to create a batch search strategy? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the elements that control material availability checks for process orders, see the page “Batch determination: Search strategy” in your participant handbook.

Task 2: Create batch search strategies with reference to your strategy type GR##. 1.

Create batch search strategies with reference to your strategy type GR##. a)

Logistics → Production Process → Process Order → Environment → Batch Search Strategy → Create Strategy type:

GR##

Enter 2.

Select key combination Order type/plant/component. a)

Key combination: X Order type/plant/component Enter


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Create strategy records for your order type PO##, plant 1100, and your materials T-RTA## and T-RTB##. a) Order type:

PO##

Plant:

1100

Material T-RTA## T-RTB## 4.

Display the detail data for both strategies and check whether the system has correctly copied the settings you made in Customizing for strategy type GR##. a)

5.

Select the line for the corresponding material and choose the Details icon.

No selection class has been assigned to the components. Choose Selection criteria to adopt selection class SEGR## assigned to your strategy type GR## for each component. Assign the following values to the characteristics as selection criteria for batch determination: Material T-RTA## Characteristic description

Value

Refractive index

1,3895 – 1,3913

Melting point Material T-RTB## Characteristic description

Value

Refractive index Melting point a) 6.

155 - 165

Select the line for the corresponding material and choose Selection criteria.

No sort sequence has been assigned to the components.


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Choose Sort to adopt sort sequence SOGR## assigned to your strategy type GR## for each component. a)

Select the line for the corresponding material and choose Sort. Save your strategy records.

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Exercise 21: Batch Determination: Applying in Process Orders Exercise Objectives After completing this exercise, you will be able to: • Perform a manual batch determination in the dialog mode • Analyze the process of batch determination

Business Example You will test the batch determination function in the process order.

Task 1: 1.

Where can you define criteria for the selection of batches for batch determination in process orders? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: In our example, we need the material components T-RTA## and T-RTB## to produce material T-HTB1##. T-RTA## and T-RTB## are raw materials and are subject to batch management. 1.

The selection criteria for batch determination have been defined as characteristic values for the BOM components in master recipe T-ASA##. Note: BOM classification overrules the selection class from the search strategy. Display the selection criteria. Write down the following: Component

Class

Characteristic value

T-RTA## T-RTB## 2.

Display the stock lists for materials T-RTA## and T-RTB## in inventory management. Continued on next page

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Which batches are available in stock? Which classification data do these batches have? Write down the following: Material

Batch

Characteristic Description

T-RTA## T-RTB## 3.

4.

Post further goods receipts for your components T-RTA## and T-RTB## as described in the following: Movement type:

501

Plant:

1100

Storage location:

0002

Material

Quantity

Batch


T-RTA##

2000

RA3051

1,3905

T-RTA##

2000

RA3052

1,3907

T-RTB##

2000

RB4042

162

T-RTB##

2000

RB4043

164

Display the stock lists for your materials T-RTA## and T-RTB## again to check the goods receipt posting.

Task 3: Create a process order of order type PO## for material T-HTB1## in plant 1100. 1.

Enter 100 000 g as the order quantity and any basic start date.

2.

Go to the material list. Determine a batch manually for material component T-RTA##.

3.

Which information message does the system issue? _____________________________________________________ Which additional option is available to define selection criteria for batch determination? _____________________________________________________ Continued on next page

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Which setting has top priority? _____________________________________________________ Confirm the info message. 4.

The batch selection screen appears. Why is batch determination carried out in the dialog mode? _____________________________________________________ _____________________________________________________

5.

Display the strategy analysis. Which batch search strategy did the system use for batch determination? _____________________________________________________ For which strategy type of the batch search procedure did the system find a strategy record (= condition record)? _____________________________________________________

6.

Display the log on batch determination. What information does the system provide on the batch determination process for component T-RTA##? _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________

7.

Which batches did the system select in stock? Write down the following: Batch

8.

Split quantity

Available qty

SLoc

Characteristic sort.

Compare the selected batches with the stock situation of material T-RTA## (see exercises 2-2, 2-3). Why did the system not select batch RA3052? ______________________________________________________ Compare the classification data for the batches selected with the selection criteria. Continued on next page

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Why does the system propose the stock of batch RA3051 as the stock to be used to cover the requirements quantity? ______________________________________________________ Display the assigned sort rule in the strategy information.

10. Compare the strategy information with the strategy you have created for the key combination Order type PO##/plant 1100/material T-RTA## (see the exercise “Batch Determination: Batch Search Strategy”, exercise 2). 11. Copy the batch determination result to your process order.

Task 4: In the following scenario, batch determination is to take place using the selection criteria of your selection class SEGR##. 1.

Therefore, delete the class assignments for components T-RTA## and T-RTB## in the BOM for recipe T-ASA##.

Task 5: Create another process order of order type PO## for material T-HTB1## in plant 1100. 1.

Enter 100 000 g as the order quantity and any basic start date.

2.

Go to the material list. Determine a batch manually for material component T-RTA##.

3.

Which information message does the system issue in this scenario? ______________________________________________________

4.

Analyze batch determination for this scenario in the same way as in exercise 3. Now the value ranges of selection class SEGR## are used as the criteria for batch selection.

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Solution 21: Batch Determination: Applying in Process Orders Task 1: 1.

Where can you define criteria for the selection of batches for batch determination in process orders? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the criteria for the selection of batches for batch determination in process orders, see the page “Batch determination in process orders” in your participant handbook.

Task 2: In our example, we need the material components T-RTA## and T-RTB## to produce material T-HTB1##. T-RTA## and T-RTB## are raw materials and are subject to batch management. 1.

The selection criteria for batch determination have been defined as characteristic values for the BOM components in master recipe T-ASA##. Note: BOM classification overrules the selection class from the search strategy. Display the selection criteria. Write down the following:


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Component

SCM340

Class


T-RTA## T-RTB## a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Display Recipe Group: T-ASA## Choose Enter. The operation overview appears. Choose the Materials tab. Choose BOM. Select the relevant BOM item and choose Extras → Batch Classification.

2.

Component

Class


T-RTA##

N-001

Refractive index 1.3901 -1.3905

T-RTB##

N-002

Melting point 158.0 – 162.0

Display the stock lists for materials T-RTA## and T-RTB## in inventory management. Which batches are available in stock? Which classification data do these batches have? Write down the following:


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Material

Batch


T-RTA## T-RTB## a)

Logistics → Materials Management → Inventory Management → Environment → Stock → Stock Overview Material: T-RTA## or T-RTB## Execute icon Position the cursor on the list line of the batch displayed and choose Extras → Batch classification.

3.

Material

Batch


T-RTA##

RA3050

Refractive index 1.3903

T-RTB##

RB4041

Melting point 160

Post further goods receipts for your components T-RTA## and T-RTB## as described in the following: Movement type:

501

Plant:

1100

Storage location:

0002


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Material

Quantity

Batch


T-RTA##

2000

RA3051

1,3905

T-RTA##

2000

RA3052

1,3907

T-RTB##

2000

RB4042

162

T-RTB##

2000

RB4043

164

a)

(…) → Inventory Management → Goods Movement → Goods Receipt → Other Movement type:

501

Plant:

1100

Storage location:

0002

Material

Quantity

Batch

T-RTA##

2000

RA3051

T-RTA##

2000

RA3052

T-RTB##

2000

RB4042

T-RTB##

2000

RB4043

Enter The system now displays the characteristics of the above four batches one after the other for value assignment. Enter the following values for the batch characteristics. Material

Batch


T-RTA##

RA3051

1,3905

T-RTA##

RA3052

1,3907

T-RTB##

RB4042

162

T-RTB##

RB4043

164

Save your goods receipts.


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4.

Display the stock lists for your materials T-RTA## and T-RTB## again to check the goods receipt posting. a)

(…) → Inventory Management → Environment → Stock → Stock Overview Material: T-RTA## or T-RTB## Execute icon


Enter 100 000 g as the order quantity and any basic start date. a)

(...) Process Order → Create → With Material Material no.:

T-HTB1##

Production plant:

1100

Process order type:

PO##

Enter Total qty:

100,000 G

Start:


Enter 2.

Go to the material list. Determine a batch manually for material component T-RTA##. a)

Choose Materials. Select the material list item for component T-RTA## and choose Material → Batch Management → Trigger Batch Determination or the relevant icon in the toolbar at the bottom of the screen.

3.

Which information message does the system issue? _____________________________________________________ Which additional option is available to define selection criteria for batch determination? _____________________________________________________ Which setting has top priority? _____________________________________________________ Continued on next page

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Confirm the info message. a)

The system issues the following message: Batches are selected for T-RTA## according to BOM classification. As an alternative to BOM classification, you can assign a selection class to the batch search strategy. BOM classification has priority over the selection class.

4.

The batch selection screen appears. Why is batch determination carried out in the dialog mode? _____________________________________________________ _____________________________________________________ a)

Choose Enter. The Batch Determination: Select Batches screen appears. Batch determination is carried out in the dialog mode because you have made the corresponding settings in the batch search strategy (see the exercise “Batch Determination: Customizing Settings”, exercise 4, and the exercise “Batch Determination: Batch Search Strategy”, exercise 2).

5.

Display the strategy analysis. Which batch search strategy did the system use for batch determination? _____________________________________________________ For which strategy type of the batch search procedure did the system find a strategy record (= condition record)? _____________________________________________________ a)

Choose Strategy analysis. Batch search procedure:

ZZGR##

Strategy type:

GR##

Choose Back. 6.

Display the log on batch determination. What information does the system provide on the batch determination process for component T-RTA##? _____________________________________________________ _____________________________________________________ _____________________________________________________ Continued on next page

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_____________________________________________________ a)

Choose Logs. Batch records are being read ... The selection criteria from the strategy record have been overwritten Search according to selection criteria ... Availability of batches ... Batches are being sorted ... If you choose the Expand all icon, the system displays further details.

7.

Which batches did the system select in stock? Write down the following: Batch

Split quantity

Available qty

SLoc


a) Batch

Split quantity

Available quantity

SLoc


RA3051

50

2000

0002

1,3905

2000

0002

1,3903

RA3050 8.

Compare the selected batches with the stock situation of material T-RTA## (see exercises 2-2, 2-3). Why did the system not select batch RA3052? ______________________________________________________ Compare the classification data for the batches selected with the selection criteria. a)

The classification data of batch RA3052 do not match the selection criteria. Position the cursor on the relevant batch and choose Classification. The system displays a comparison of the batch classification data and the selection criteria for the relevant BOM item.


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Why does the system propose the stock of batch RA3051 as the stock to be used to cover the requirements quantity? ______________________________________________________ Display the assigned sort rule in the strategy information. a)

Due to the sort rule you defined in the batch search strategy (see the exercise “Batch Determination: Batch Search Strategy”, exercise 2-6), the system proposes to withdraw the requirements quantity from the stock of batch RA3051.

10. Compare the strategy information with the strategy you have created for the key combination Order type PO##/plant 1100/material T-RTA## (see the exercise “Batch Determination: Batch Search Strategy”, exercise 2). a)

Choose Strategy info. The system displays the assigned sort rule as well as miscellaneous other information.

11. Copy the batch determination result to your process order. a)

Choose Copy. The system copies the batch it proposed to the material list.

Task 4: In the following scenario, batch determination is to take place using the selection criteria of your selection class SEGR##. 1.

Therefore, delete the class assignments for components T-RTA## and T-RTB## in the BOM for recipe T-ASA##. a)

Logistics → Production Process → Master Data → Master Recipes → Recipe and Material List → Change Recipe group: T-ASA## Choose Enter. The operation overview appears. Choose the Materials tab. Choose BOM. Select the relevant BOM item and choose Extras → Batch Classification. Select the line for the assigned class and choose Edit → Delete. Save your master recipe. Continued on next page

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Task 5: Create another process order of order type PO## for material T-HTB1## in plant 1100. 1.



T-HTB1##

Production plant:

1100

Process order type:

PO##

Enter Total qty:

100,000 G

Start:


Enter 2.

Go to the material list. Determine a batch manually for material component T-RTA##. a)

Choose Materials. Select the material list item for component T-RTA## and choose Material → Batch Management → Trigger Batch Determination or the relevant icon in the toolbar at the bottom of the screen.

3.

Which information message does the system issue in this scenario? ______________________________________________________ a)

4.

The system issues the following message: Batches are selected for T-RTA## according to component strategy.

Analyze batch determination for this scenario in the same way as in exercise 3. Now the value ranges of selection class SEGR## are used as the criteria for batch selection. a)

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Exercise 22: Batch Determination: Batch Entry Scenarios Exercise Objectives After completing this exercise, you will be able to: • Set various batch entry scenarios for the components of your process orders

Business Example You will test different batch determination scenarios.

Task 1: Enter the MRP 2 view of your material T-RTA## in plant 1100 in the change mode. 1.

Enter the MRP 2 view of your material T-RTA## in plant 1100 in the change mode.

2.

Which function does the Batch entry indicator have? _____________________________________________________ _____________________________________________________

3.

Which options are available for this indicator? _____________________________________________________ _____________________________________________________ _____________________________________________________

4.

Assign the value 1 to the Batch entry indicator. Save the material master record.


Create a process order of order type PO## for material T-HTB1## in plant 1100. Enter 100 000 g as the order quantity and any basic start date.

2.

Try to release the order. Which message does the system issue? _____________________________________________________ Display the log on order release. Why can you not release the order? Continued on next page

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_____________________________________________________ 3.

Manually carry out batch determination for component T-RTA##.

4.

Now try to release the order again. Can you release the order now? _____________________________________________________

Task 3: 1.

Assign the value 2 to the Batch entry indicator for your material T-RTA##.

Task 4: Create a process order for material T-HTB1##. Enter 100 000 g as the order quantity and any basic start date. 1.

Create a process order for material T-HTB1##. Enter 100 000 g as the order quantity and any basic start date.

2.

Release the order. Save your order and write down the order number: ___________________

3.

Try to post a goods issue for your material component T-RTA## for this order. Use movement type 261. Withdraw the material from storage location 0002 of plant 1100. Which error message does the system issue? _____________________________________________________

4.

Enter your process order in the change mode and manually carry out batch determination for component T-RTA#. Save the order.

5.

Again, try to post a goods issue for your material component T-RTA##. Can you now post a goods issue for the order? _____________________________________________________

Task 5: 1.

Assign the value 3 to the Batch entry indicator for your materials T-RTA## and T-RTB##. Continued on next page

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Task 6: Create a process order for material T-HTB1##. Enter 100 000 g as the order quantity. 1.

Create a process order for material T-HTB1##. Enter 100 000 g as the order quantity.

2.

Release the order. Display the material list after you have released the order. What do you notice? _____________________________________________________ _____________________________________________________

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Solution 22: Batch Determination: Batch Entry Scenarios Task 1: Enter the MRP 2 view of your material T-RTA## in plant 1100 in the change mode. 1.

Enter the MRP 2 view of your material T-RTA## in plant 1100 in the change mode. a)

(…) Material → Change → Immediately Material: T-RTA## Enter Go to the MRP 2 view. Enter Go to plant 1100. Enter

2.

Which function does the Batch entry indicator have? _____________________________________________________ _____________________________________________________ a)

3.

For information on the different options for the Batch entry indicator, see the page “Settings in the Material Master Record” in your participant handbook.

Which options are available for this indicator? _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

4.

For information on the different options for the Batch entry indicator, see the page “Settings in the Material Master Record” in your participant handbook.

Assign the value 1 to the Batch entry indicator. Save the material master record. a)

Batch entry: 1 Save the material master record.


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Create a process order of order type PO## for material T-HTB1## in plant 1100. Enter 100 000 g as the order quantity and any basic start date. a)


T-HTB1##

Production plant:

1100

Process order type:

PO##

Enter Total qty:

100,000 G

Start:


Enter 2.

Try to release the order. Which message does the system issue? _____________________________________________________ Display the log on order release. Why can you not release the order? _____________________________________________________ a)

Choose the Release icon The system issues the message: Release rejected (check log). Goto → Logs → Release Choose Error messages. The log contains the message: You must enter the batch for material T-RTA##.

3.

Manually carry out batch determination for component T-RTA##. a)

4.

See exercise

Now try to release the order again. Can you release the order now?


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_____________________________________________________ a)

After batch determination for component T-RTA##, you can release the order.

Task 3: 1.

Assign the value 2 to the Batch entry indicator for your material T-RTA##. a)

Change material T-RTA##; MRP 2 view; plant 1100: Batch entry: 2

Task 4: Create a process order for material T-HTB1##. Enter 100 000 g as the order quantity and any basic start date. 1.

Create a process order for material T-HTB1##. Enter 100 000 g as the order quantity and any basic start date. a)

(...) Process Order → Create → With Material Material number:

T-HTB1##

Production plant:

1100

Process order type:

PO##

Enter Total quantity:

100,000 G

Start:


Enter 2.

Release the order. Save your order and write down the order number: ___________________ a)

Choose the Release icon Save your order.

3.

Try to post a goods issue for your material component T-RTA## for this order. Use movement type 261. Withdraw the material from storage location 0002 of plant 1100. Continued on next page

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Which error message does the system issue? _____________________________________________________ a)

(…) → Process Order → Environment → Material Movement → Withdraw Material Movement type:

261

Plant:

1100

Storage location:

0002

Choose To order ... Enter the order number from exercise 4-2. Choose Enter. The Enter Goods Issue: Selection Screen appears. The system offers you the two material components T-RTA## and T-RTB##. Select component T-RTA## and save. The system displays the error message: No batch specified in production order. 4.

Enter your process order in the change mode and manually carry out batch determination for component T-RTA#. Save the order. a)

5.

See exercise

Again, try to post a goods issue for your material component T-RTA##. Can you now post a goods issue for the order? _____________________________________________________ a)

After you have carried out batch determination for component T-RTA## in the order, you can post a goods issue for the order for this component.

Task 5: 1.

Assign the value 3 to the Batch entry indicator for your materials T-RTA## and T-RTB##. a)

Change materials T-RTA## and T-RTB##; MRP 2 view; plant 1100: Batch entry: 3


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Task 6: Create a process order for material T-HTB1##. Enter 100 000 g as the order quantity. 1.

Create a process order for material T-HTB1##. Enter 100 000 g as the order quantity. a)


T-HTB1##

Production plant:

1100

Process order type:

PO##

Enter Total qty:

100,000 G

Start:


Enter 2.

Release the order. Display the material list after you have released the order. What do you notice? _____________________________________________________ _____________________________________________________ a)

Choose the Release icon Choose Materials. The system automatically carried out batch determination for material components T-RTA## and T-RTB## during order release

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Lesson Summary You should now be able to: • Explain the Customizing settings for batch determination • Create a batch search strategy • Make the appropriate settings for batch determination in the material master records of your material components • Carry out batch determination for your process order

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Lesson: Batch Determination and Material Quantity Calculation Lesson Overview This lesson provides you with an example scenario for using the material quantity calculation with reference to batch determination processes.


Carry out a sample scenario on how to use the functions of batch determination, active ingredient management, and material quantity calculation together.

Business Example You produce fruit juice in your company. In recipe maintenance, the planners specify the quantities of material components that are subject to batch management in proportion units (active ingredient units of measure). The dependencies between the production quantity and the component quantities are defined in formulas of material quantity calculation. In process order execution, the system recalculates the production quantity and component quantities based on the batches assigned in batch determination.

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Lesson: Batch Determination and Material Quantity Calculation

Material Quantity Calculation

Figure 49: Material Quantity Calculation

In material quantity calculation, you define formulas to calculate the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the ingredients, yield ratios of the products and by-products as well as specific batch properties (for example, concentration, active ingredient content). You can also define formulas for calculating phase quantities in material quantity calculation. By using batch determination together with material quantity calculation, you can perform active ingredient management in a process order.

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Batch Determination and Material Quantity Calculation: Basic Process

Figure 50: Batch Determination and Material Quantity Calculation: Basic Process

Master Recipe for the Sample Scenario

Figure 51: Master Recipe for the Sample Scenario

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Proportion Quantities (Active Ingredient Quantities) and Batches

Figure 52: Proportion Quantities (Active Ingredient Quantities) and Batches

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Batch Determination and Material Quantity Calculation: Sample Scenario (I)

Figure 53: Batch Determination and Material Quantity Calculation: Sample Scenario (I)

After the process order has been created, the planned quantities and planned characteristic values for the Fruit juice product and the material components are available. In our scenario, the values of the Fruit content and Acidity characteristics of the Fruit juice product are the fixed target values of production. All other values are variable. After the process order has been created, batch determination is carried out for the Fruit premix component in our scenario. Batch determination settings specify that the batches must always be used up. The batches are available in containers of 1200 L. You must withdraw enough containers so that you do not fall below the planned production quantity. An overdelivery is allowed.

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Batch Determination and Material Quantity Calculation: Sample Scenario (II)

Figure 54: Batch Determination and Material Quantity Calculation: Sample Scenario (II)

Since production requirements make it necessary to withdraw more fruit premix and since the characteristic values of the assigned batch deviate from the planned values, material quantity calculation must be used to recalculate the production quantities for the Fruit juice, the proportion quantities for the Lemon juice, and the Sugar and Water quantities.

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Batch Determination and Material Quantity Calculation: Sample Scenario (III)

Figure 55: Batch Determination and Material Quantity Calculation: Sample Scenario (III)

Afterwards, a batch determination is carried out for the citric acid based on the recalculated proportion quantity. In our scenario, the required quantity is charged from a big storage tank.

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Batch Determination and Material Quantity Calculation: Sample Scenario (IV)

Figure 56: Batch Determination and Material Quantity Calculation: Sample Scenario (IV)

Then the material quantity is used to recalculate the Water quantity that needs to be added based on the production quantity (Fruit juice) and the added quantities of Fruit premix and Lemon juice.

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Exercise 23: Batch Determination and Material Quantity Calculation Exercise Objectives After completing this exercise, you will be able to: • Perform quantity planning using the material quantity calculation • Work with proportion quantities for material components in the process order • Use batch determination together with material quantity calculation

Business Example You manufacture fruit juice in your company that meets the following requirements: The fruit juice's fruit content should be 35 % and its acidity should be 2 %. You need the components fruit premix, lemon juice, water and sugar to produce the fruit juice. The fruit premix and lemon juice are subject to batch management. The fruit premix batches have been assigned the characteristics Fruit content and Acidity. The lemon juice batches have been assigned the characteristic Acidity. The characteristic values of the fruit premix batches and lemon juice batches available in stock usually vary enormously. To obtain the target values Fruit content 35 % and Acidity 2% for your product fruit juice, you have defined formulas in material quantity calculation of the master recipe to be used. These formulas map the necessary dependencies between the material quantities with regard to the batch characteristic values onto the system. Process planning for the fruit juice production is typically carried out as follows in the process order: After the process order has been created, batch determination is triggered for the fruit premix. The fruit premix is available in 1200-liter barrels, which must always be used up completely. The proportion quantity LF (liter fruit) required according to the planning must at least be complied with. This means that usually more fruit premix is withdrawn. Due to this excess withdrawal and the batch characteristic values that deviate from the planning, the product quantity and the material component quantities must be adjusted in material quantity calculation. Afterwards, batch determination is carried out for the lemon juice according to the recalculated quantities. Since the characteristic values usually differ from the planned values here as well, material quantity calculation must then be carried out once again to be able to adjust the water quantity accordingly and guarantee the target values.

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The order can now be released.

Task 1: Master recipe 1.

Display master recipe T-JUI##.

2.

Write down the recipe description. _____________________________________________________

3.

Display the material assignments for the recipe. Which material has been assigned as the product? Material: _____________________________________________ Material description: ______________________________________

4.

Navigate to the material list. Which material components have been assigned? Material

5.

Item text

Call up material quantity calculation for the recipe. Write down the planned quantities and characteristic values defined in material quantity calculation. Object

1:Qty

UOM

2:Fruit content

UOM

3:Acidity

UOM

T-FJU## T-RJU1## T-RJU2## T-RI5## T-RJU3## Note: Formulas have been maintained for the objects with the formula indicator a/b. These formulas define the above-mentioned dependencies between the material quantities and batch characteristics. Continued on next page

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To display the formulas choose the Formula overview icon. These formulas have been explained in more detail in the training course PLM115 Basic Data for Process Manufacturing.

Task 2: Process order 1.

Create a process order for material T-FJU## in plant 1100. Choose order type PI01. Enter 5,000 L as the order quantity and any basic start date.

2.

Material quantities after order creation Display the material list for the order after order creation. Write down the following: Material

Reqmts quantity

Unit of measure

Compare the requirements quantities with the planned quantities in material quantity calculation in exercise 1-5. How would you interpret the result? 3.

Batch determination for fruit premix T-RJU1## Create a second session. Display the stock overview for material T-RJU1## Fruit premix in plant 1100 in the second session. Access the stock overview twice. When you access it the first time, enter L (liter) as the proportion quantity. The second time, enter LF (liter fruit). Write down the following information about the existing batches:


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Batch number

Unrestricted use (unit of measure L)

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Unrestricted use (unit of measure LF)

Fruit content

Acidity

End the second session. 4.

Carry out batch determination for the material component T-RJU## Fruit premix. Write down the following information from the material list after batch determination: Material

Reqmts quantity Unit of measure Batch

T-RJU1##

--------------------

LF

T-RJU1##

LF

T-RJU1##

LF

--------------------

Compare the batch determination result with the original requirements quantity (exercise 2-2) and the existing stocks (exercise 2-3). Interpret the result. According to which criteria was the batch assigned? _____________________________________________________ _____________________________________________________ _____________________________________________________ 5.

Material quantity calculation: Adjusting the product quantity of material T-FJU## and the component quantities in accordance with the assigned batches of component T-RJU1## Call up material quantity calculation. Adjust the product quantity in accordance with the above assigned batch quantities and characteristics of component T-RJU1##. The component quantities are also adjusted at the same time. Compare the order's present product and component quantities in material quantity calculation with the values after order creation (exercise 2-2). Copy the material quantity calculation result to your order.


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6.

Batch determination for lemon juice T-RJU2##; material quantity calculation: Adjusting the water quantity T-RI5## Carry out batch determination for the material component T-RJU2## Lemon juice.

7.

Then call up material quantity calculation to adjust the required water quantity. The formulas are executed automatically. Copy the material quantity calculation result to your order. Compare the order header quantity and the component quantities with the quantities after order creation (see exercise 2-2). Result: You can now release and process the order. The batch quantities and material quantities determined by material quantity calculation are now staged. In addition, an increase in the quantity of goods received is expected in the stock/requirements list for product T-FJU## Fruit juice.

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Solution 23: Batch Determination and Material Quantity Calculation Task 1: Master recipe 1.

Display master recipe T-JUI##. a)

(…) → Recipe and Material List → Display Recipe group: T-JUI##

2.

Write down the recipe description. _____________________________________________________ a)

3.

Description: Fruit juice

Display the material assignments for the recipe. Which material has been assigned as the product? Material: _____________________________________________ Material description: ______________________________________ a)

Recipe header tab page Choose Material assignments Material: T-FJU## Material description: Fruit juice

4.

Navigate to the material list. Which material components have been assigned?


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Material

a)

Item text

Recipes tab page Materials icon The Materials tab appears.

5.

Material

Item text

T-RJU1##

Fruit premix

T-RJU2##

Lemon juice

T-RI5##

Treated water

T-RJU3##

Sugar

Call up material quantity calculation for the recipe. Write down the planned quantities and characteristic values defined in material quantity calculation. Object

1:Qty

UOM

2:Fruit content

UOM

3:Acidity

UOM

T-FJU## T-RJU1## T-RJU2## T-RI5## T-RJU3## Note: Formulas have been maintained for the objects with the formula indicator a/b. These formulas define the above-mentioned dependencies between the material quantities and batch characteristics. To display the formulas choose the Formula overview icon.


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These formulas have been explained in more detail in the training course PLM115 Basic Data for Process Manufacturing. a)

Choose the a/b (Material quantity calc.) icon. Object

1:Qty

UOM

2:Fruit UOM content

3:Acidity

UOM

T-FJU##

-1000

L

35

%

2

%

T-RJU1## 350

LF

80

%

3

%

T-RJU2## 6,875

LS

40

%

T-RI5##

L

545

T-RJU3## 10

KG

Task 2: Process order 1.

Create a process order for material T-FJU## in plant 1100. Choose order type PI01. Enter 5,000 L as the order quantity and any basic start date. a)


T-FJU##

Production plant:

1100

Process order type:

PI01

Enter Total quantity: 2.

5000 L

Material quantities after order creation Display the material list for the order after order creation. Write down the following:


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Material

Reqmts quantity

Unit of measure

Compare the requirements quantities with the planned quantities in material quantity calculation in exercise 1-5. How would you interpret the result? a)

Choose Materials. Material

Reqmts quantity

Unit of measure

T-RJU1##

1750

LF

T-RJU2##

34,375

LS

T-RI5##

2727

L

T-RJU3##

50

KG

Material quantity calculation was carried out at order creation. The planned quantities from material quantity calculation that were originally based on 1000 L have been adjusted to the production quantity of 5000 L. 3.

Batch determination for fruit premix T-RJU1## Create a second session. Display the stock overview for material T-RJU1## Fruit premix in plant 1100 in the second session. Access the stock overview twice. When you access it the first time, enter L (liter) as the proportion quantity. The second time, enter LF (liter fruit). Write down the following information about the existing batches:


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Batch number


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Fruit content

Acidity

End the second session. a)

System → Create session Logistics → Materials Management → Inventory Management → Environment → Stock → Stock Overview Material:

T-RJU1##

Plant:

1100

Display unit of measure:

L (first access); LF (second access)

Execute icon To display the batch characteristics, choose Extras → Batch classification. Batch number



Fruit content

Acidity

Batch number

1200

1080

90 %

4%

Batch number

1200

960

80 %

3%

Delete the second session. System → Delete session 4.

Carry out batch determination for the material component T-RJU## Fruit premix. Write down the following information from the material list after batch determination: Continued on next page

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Material

Reqmts quantity Unit of measure Batch

T-RJU1##

--------------------

LF

T-RJU1##

LF

T-RJU1##

LF

--------------------

Compare the batch determination result with the original requirements quantity (exercise 2-2) and the existing stocks (exercise 2-3). Interpret the result. According to which criteria was the batch assigned? _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Choose the Execute batch determination icon. Material

Reqmts quantity

Unit of measure

Batch

T-RJU1##

-------------------- LF

--------------------

T-RJU1##

1080

LF

Batch number

T-RJU1##

960

LF

Batch number

The stock quantities of the two batches for material T-RJU1## have been assigned completely. In our scenario, the batches for the fruit premix RJU1## are assigned according to the following criteria: 1. 2.

5.

Assigned batches must be used up completely. The planned requirements quantity must at least be covered. An overdelivery that may occur because the assigned batches must be used up is allowed.

Material quantity calculation: Adjusting the product quantity of material T-FJU## and the component quantities in accordance with the assigned batches of component T-RJU1## Call up material quantity calculation. Adjust the product quantity in accordance with the above assigned batch quantities and characteristics of component T-RJU1##. The component quantities are also adjusted at the same time.


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Compare the order's present product and component quantities in material quantity calculation with the values after order creation (exercise 2-2). Copy the material quantity calculation result to your order. a)

Material quantity calculation icon Choose Calculate product quantity. After you analyze the result: Choose the Save formula and copy result icon.

6.

Batch determination for lemon juice T-RJU2##; material quantity calculation: Adjusting the water quantity T-RI5## Carry out batch determination for the material component T-RJU2## Lemon juice. a)

For lemon juice T-RJ2##: Choose the Execute batch determination icon.

7.

Then call up material quantity calculation to adjust the required water quantity. The formulas are executed automatically. Copy the material quantity calculation result to your order. Compare the order header quantity and the component quantities with the quantities after order creation (see exercise 2-2). Result: You can now release and process the order. The batch quantities and material quantities determined by material quantity calculation are now staged. In addition, an increase in the quantity of goods received is expected in the stock/requirements list for product T-FJU## Fruit juice. a)

Material quantity calculation icon The formulas are executed automatically. Choose the Save formula and copy result icon.

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Lesson Summary You should now be able to: • Carry out a sample scenario on how to use the functions of batch determination, active ingredient management, and material quantity calculation together.

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Lesson: Resource Reservation Lesson Overview This lesson gives you an overview of the objectives and methods of resource reservation (capacity requirements planning).


Name the different options for making resource reservations Describe the basics and the general process of resource reservation (capacity requirements planning) Dispatch operations in the capacity planning table of the ECC system Perform system-aided resource selection in the ECC System

Business Example You will get an overview of the alternative ways to realize resource reservations with the SAP System. You will test the function for dispatching operations at resources in the ECC capacity planning table. In doing so, you will use the resource selection function.

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Lesson: Resource Reservation

Resource Reservation

Figure 57: Resource Reservation

Detailed scheduling (resource/work center scheduling) can be performed both in ECC (capacity requirements planning) and in SCM(APO) (PP/DS). A prerequisite for all methods of detailed scheduling should be long-term or medium-term capacity requirements planning. You can use the order information system to easily generate a list of the operations per resource. For this purpose, you must set up a special layout.

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Basics and Process

Figure 58: Basics and Process

The available capacity describes the availability of a resource with regard to time. The capacity requirement specifies the time requirement an operation of an order has regarding a resource to be used. The following activities usually determine the process of resource reservation (capacity requirements planning): • • • •

294

Definition of available capacities of resources (master data maintenance) Calculation of the capacity requirements of operations in orders Capacity evaluation: comparison of available capacities and capacity requirements Capacity leveling: dispatching of operations at resources, guaranteeing of available capacity for a specific time


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Resource Reservation Using the Capacity Planning Table

Figure 59: Resource Reservation Using the Capacity Planning Table

The graphical planning tables in the ECC and SCM(APO) systems enable you to carry out capacity requirements planning over time. They can be used interactively and enable you to dispatch operations or activities (APO) at available capacities of resources at exact points in time. Depending on your request and system (ECC or APO), the data can be prepared according to different views (for example, the capacity situation of a resource or the capacity situation of all resources required for an order) and displayed in different charts. The planning table is made up of different charts in which the available capacity and capacity requirements are grouped according to different criteria and are displayed over a common time axis. Each chart has a title bar and comprises a table section and a diagram section: • •

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The table section contains information on the identification and description of the objects displayed in the diagram section. The diagram section is a window on the time axis, providing a graphic presentation of the available capacity or capacity requirements with start and finish dates.


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Resource Selection in ECC

Figure 60: Resource Selection in ECC

The following functions are only available in the ECC System: • •

•

296

You can use the resource selection function to find suitable resources for carrying out an operation at the time of production. In system-aided resource selection, the system compares the characteristic values maintained for the resources and operations (classification in class type 019 Work center class). The resource network, representing the physical connection of resources, can be taken into account during resource selection.


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Exercise 24: Resource Reservation: Overview Exercise Objectives After completing this exercise, you will be able to: • Explain the objectives, methods, basics and the general process of resource reservation with SAP

Business Example You will get an overview of the objectives, methods, basics, and general process of resource reservation with SAP.

Task: 1.

Which goals do you want to reach by creating a resource schedule? Which options are available in SAP to reach these goals? Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

2.

Describe the basics and basic process of capacity requirements planning with SAP. Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Continued on next page

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___________________________________________________________ ___________________________________________________________

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Solution 24: Resource Reservation: Overview Task: 1.

Which goals do you want to reach by creating a resource schedule? Which options are available in SAP to reach these goals? Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

2.

For information on the goals of resource reservations, see the page “Resource Reservation” in your participant handbook.

Describe the basics and basic process of capacity requirements planning with SAP. Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

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For information on the basics and the process of capacity requirements planning with SAP, see the page “Basics and Process” in your participant handbook.


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Exercise 25: Resource Reservation Using the Capacity Planning Table in the ECC System Exercise Objectives After completing this exercise, you will be able to: • Describe the function and structure of the capacity planning table • Dispatch operations in the capacity planning table • Use the system-supported resource selection

Business Example You will create a process order and display the capacity requirements and available capacity for the operations in the ECC capacity planning table. You will dispatch an operation in the capacity planning table. You will carry out system-aided resource selection for this operation.

Task 1: 1.

Outline the functions and basic structure of the capacity planning table. Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: 1.

Display the master recipe of recipe group T-RC1##.

2.

Display the material/recipe assignment. Continued on next page

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The recipe describes the production of which material? ______________________________________________________ 3.

Navigate to the operation overview. Which operations have been created in the recipe? Which resources are assigned to these operations? Write down the following: Operation, Phase

4.

Resource

Description

Navigate to the recipe header. Display the resource network that has been assigned to the recipe. Copy down the resource network:

5.

Compare the resources in the resource network with those assigned in the operation overview. What do you notice? _____________________________________________________ _____________________________________________________ Note: Resource T-GT1## is used provisionally for one of the available reaction vessels of the resource network. The task list usage restricts the usage of this resource to the process planning stage. Before you release an order, you must replace the planning resource with a physically existing resource from the resource network. You can, for example, do this during capacity requirements planning. To use system-aided resource selection, you can define resource selection conditions for the corresponding operation. In the process order, the system uses the resource selection function to compare these selection conditions with the attributes of the resources in the resource network and to propose suitable resources.

6.

Display the resource selection conditions for operation 200 REACTION.


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Class

7.


Display the classification data of reaction vessels T-RT1##, T-RT2##, and T-RT3## of the resource network to compare them with the selection conditions. Write down the following: Resource

Class


T-RT1## T-RT2## T-RT3##

Task 3: 1.

Create a process order of order type PO## for material T-FF1## in plant 1100. Enter 10,000 L as the quantity to be produced. Enter today's date as the basic start date.

2.

Try to release the order. Which message does the system issue? _____________________________________________________ Which status information do you get? _____________________________________________________ Display the status for operation 200. What does the status WCRE mean? _____________________________________________________

3.

Display the release log and write down the error messages. _____________________________________________________ _____________________________________________________ _____________________________________________________ Continued on next page

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_____________________________________________________ Save your order.

Task 4: You now want to carry out resource selection for operation 200. The reaction vessels represent critical bottleneck resources of your production line as far as the capacity load is concerned. For this reason, you carry out resource selection during capacity requirements planning in the capacity planning table. Note:This exercise only aims at demonstrating the basic principles of capacity requirements planning. For this reason, we will only look at one process order in the capacity planning table. 1.

Enter the capacity planning table from the resource view. Enter plant 1100 and capacity planner group V## as the selection criteria.

2.

First, get an overview of the elements, functions, and environment of the capacity planning table.

3.

For which resources does the system display available capacities in the Resources chart? Resources Resource

4.

Description

For which process orders and operations does the system display capacity requirements in the Pool chart? Pool Material

5.

Order

Operation

Choose Hourly period split as the scale for the planning table. Search for your operations in the Pool chart. Continued on next page

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Enlarge the display if necessary.

Task 5: 1.

To which resource has operation 200 been assigned? ___________________________________________________________

Task 6: 1.

Try to dispatch operation 200. Why does the system not dispatch the operation? Analyze the planning log. ___________________________________________________________ ___________________________________________________________

Task 7: 1.

To be able to dispatch operation 200, you must first carry out resource selection to replace the provisional resource T-GT1## with a physically existing resource. Enter your process order in the change mode from the capacity planning table.

2.

Go to the operation overview and carry out resource selection for operation 200.

3.

Which resources does the system offer you in resource selection? ______________________________________________________ ______________________________________________________

4.

In resource selection, display the classification data of the suggested resources, the selection conditions defined for the operation, and the resource network. Choose one of the resources. Exit the order and go back to the capacity planning table.


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Task 8: 1.

Use the Dispatch planning table function to dispatch operation 200.

2.

Display the dispatched operation in the change mode from the planning table. Which new operation status has been set due to dispatching? _____________________________________________________

3.

Go to the order header and try to reschedule the order. Delete the basic finish date and modify the basic start date so that it is one week later. Now try to schedule the order again. What do you notice? _____________________________________________________ Why can you not reschedule the order? Display the scheduling log to answer this question. _____________________________________________________ Go back to the planning table.

4.

Manually move the dispatched operation towards the future. What happens to the operations that have not yet been dispatched? _____________________________________________________ _____________________________________________________ Save your plan.

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Solution 25: Resource Reservation Using the Capacity Planning Table in the ECC System Task 1: 1.

Outline the functions and basic structure of the capacity planning table. Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the function and basic structure of the capacity planning table, see the page “Resource Reservation Using the Capacity Planning Table” in your participant handbook.

Task 2: 1.

Display the master recipe of recipe group T-RC1##. a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Display Recipe Group:

2.

T-RC1##

Display the material/recipe assignment. The recipe describes the production of which material?


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______________________________________________________ a)

Choose Recipe header. Choose Material Assignments. Recipe 1 of recipe group T-RC1## describes the production of material T-FF1## , Fertilizer, liquid, form A.

3.

Navigate to the operation overview. Which operations have been created in the recipe? Which resources are assigned to these operations? Write down the following: Operation, Phase

a)

Resource

Description

Choose the Recipes tab. Choose the Operations icon.

4.

Operation

Resource

Description

100

T-MT1##

CHARGING

200

T-GT1##

REACTION

300

T-ST1##

SEPARATION

Navigate to the recipe header. Display the resource network that has been assigned to the recipe. Copy down the resource network: a)

Choose the Recipe header tab. Choose the Res. Network Graphic icon.

5.

Compare the resources in the resource network with those assigned in the operation overview. What do you notice? _____________________________________________________ _____________________________________________________ Note: Continued on next page

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Resource T-GT1## is used provisionally for one of the available reaction vessels of the resource network. The task list usage restricts the usage of this resource to the process planning stage. Before you release an order, you must replace the planning resource with a physically existing resource from the resource network. You can, for example, do this during capacity requirements planning. To use system-aided resource selection, you can define resource selection conditions for the corresponding operation. In the process order, the system uses the resource selection function to compare these selection conditions with the attributes of the resources in the resource network and to propose suitable resources. a)

None of the reaction vessels T-RT*## has been assigned to operation 200 REACTION. Instead, resource T-GT1## has been assigned. However, this resource is not contained in the resource network. Read the information in the note for this exercise.

6.

Display the resource selection conditions for operation 200 REACTION. Class

a)


Select operation 200 REACTION in the operation overview and choose Goto → Respource selection condition or the corresponding button in the toolbar at the bottom of the screen. Class


REAK_00

Surface coating polyethylene coated Rounds per minute 100

7.

Display the classification data of reaction vessels T-RT1##, T-RT2##, and T-RT3## of the resource network to compare them with the selection conditions. Write down the following: Resource

Class


T-RT1##


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Class


T-RT2## T-RT3##

a)

Logistics → Production - Process → Master Data → Resources → Resource → Display Plant:

1100

Resource:

T-RT1## or T-RT2## or T-RT3##

Enter Choose Classifiation (at the bottom of the screen) Resource

Class


T-RT1##

REAK_00

Surface coating glass coated Rounds per minute 50 - 150

T-RT2##

REAK_00

Surface coating polyethylene coated Rounds per minute 50 - 150

T-RT3##

REAK_00

Surface coating polyethylene coated Rounds per minute 50 - 150

Task 3: 1.

Create a process order of order type PO## for material T-FF1## in plant 1100. Enter 10,000 L as the quantity to be produced.


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Enter today's date as the basic start date. a)


T-FF1##

Production plant:

1100

Process order type:

PO##

Enter Total qty:

10,000 L

Start:

Today

Enter 2.

Try to release the order. Which message does the system issue? _____________________________________________________ Which status information do you get? _____________________________________________________ Display the status for operation 200. What does the status WCRE mean? _____________________________________________________ a)

Choose the Release icon The Status Processing: Release dialog box appears in which the system informs you that the business transaction cannot be carried out. Choose Status information. The following message is displayed: System status WCRE is active. Double-click the message line to display more detailed information. Go to the operation overview. Double-click the System status field for operation 200: WCRE Work center until release

3.

Display the release log and write down the error messages. _____________________________________________________ _____________________________________________________ Continued on next page

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_____________________________________________________ _____________________________________________________ Save your order. a)

Goto → Logs → On release Choose Error messages. Resource T-GT1## in operation 200 can only be used until release. Resource T-GT1## in operation 200 is not in resource network. Resource T-GT1## in operation 200 does not meet resource selection criteria. System status WCRE is active Save your order.

Task 4: You now want to carry out resource selection for operation 200. The reaction vessels represent critical bottleneck resources of your production line as far as the capacity load is concerned. For this reason, you carry out resource selection during capacity requirements planning in the capacity planning table. Note:This exercise only aims at demonstrating the basic principles of capacity requirements planning. For this reason, we will only look at one process order in the capacity planning table. 1.

Enter the capacity planning table from the resource view. Enter plant 1100 and capacity planner group V## as the selection criteria. a)

Logistics → Production-Process → Process Planning → Capacity Leveling → Resource View → Capacity Planning Table Plant:

1100

Capacity planner grp:

V##

Choose Enter. The system loads the capacity planning table with the capacity requirements and available capacities that match your selection criteria. 2.

First, get an overview of the elements, functions, and environment of the capacity planning table. a)

See exercise


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3.

For which resources does the system display available capacities in the Resources chart? Resources Resource

Description

a) Resources

4.

Resource

Description

T-GT1##

Reaction vessel group

T-MT1##

Charge vessel

T-RT1##

Reaction vessel 1

T-RT2##

Reaction vessel 2

T-RT3##

Reaction vessel 3

T-ST1##

Separation vessel

For which process orders and operations does the system display capacity requirements in the Pool chart?


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Pool Material

Order

Operation

a) Pool

5.

Material

Order

Operation

T-FF1##

Order number

100

T-FF1##

Order number

200

T-FF1##

Order number

300

Choose Hourly period split as the scale for the planning table. Search for your operations in the Pool chart. Enlarge the display if necessary. a)

Settings → Scale → Hourly period split To search for operations, select a line in the Pool chart and choose GrafObj. To enlarge the display, choose the Zoom in icon.

Task 5: 1.

To which resource has operation 200 been assigned? ___________________________________________________________ a)

The information is displayed in the text area in the Pool chart. Operation 200 is assigned to resource (=WrkCntr) T-GT1##, the provisional resource.

Task 6: 1.

Try to dispatch operation 200. Why does the system not dispatch the operation? Continued on next page

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Analyze the planning log. ___________________________________________________________ ___________________________________________________________ a)

Select the icon for operation 200 in the pool and choose the Dispatch icon in the standard toolbar. The system does not dispatch the operation. Choose Plan.log. Choose Error messages. Display the long text for the error message (Long text icon). The system tells you to check the status logic of the relevant object, which in our case is operation 200.

Task 7: 1.

To be able to dispatch operation 200, you must first carry out resource selection to replace the provisional resource T-GT1## with a physically existing resource. Enter your process order in the change mode from the capacity planning table. a)

2.

Select a line in the text area of the Pool chart and choose the Order icon.

Go to the operation overview and carry out resource selection for operation 200. a)

Choose Operations. Select operation 200 and choose Operation → Functions for phase / for operation → Resource selection Or choose Execute resource selection

3.

Which resources does the system offer you in resource selection? ______________________________________________________ ______________________________________________________ a)

T-RT2## Reaction vessel 2, polyethylene coated T-RT3## Reaction vessel 3, polyethylene coated


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In resource selection, display the classification data of the suggested resources, the selection conditions defined for the operation, and the resource network. Choose one of the resources. Exit the order and go back to the capacity planning table. a)

Position the cursor on one of the resources the system offers and choose Classification to display the classification data. Choose Selection cond. to display the selection conditions that have been defined for operation 200. Choose Resource network to display the resource network. Position the cursor on one of the resources the system offers and choose Choose. In the operation overview, the system replaces the provisional planning resource T-GT1## by the resource you have selected. Go back to the planning table.

Task 8: 1.

Use the Dispatch planning table function to dispatch operation 200. a)

2.

Select operation 200 and choose the Dispatch icon.

Display the dispatched operation in the change mode from the planning table. Which new operation status has been set due to dispatching? _____________________________________________________ a)

Choose Operations. Choose the Status icon for the operation status. The new operation status DSPT Dispatched has been assigned.

3.

Go to the order header and try to reschedule the order. Delete the basic finish date and modify the basic start date so that it is one week later. Now try to schedule the order again. What do you notice? _____________________________________________________ Why can you not reschedule the order? Display the scheduling log to answer this question. _____________________________________________________ Continued on next page

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Go back to the planning table. a)

The order was not rescheduled starting from the new start date. The order dates are the same as the original dates. Goto → Logs → On scheduling Choose Information messages. The scheduling log informs you that operation 200 and the related phases have been dispatched. This means that the operation is fixed and cannot be moved by scheduling. Go back to the planning table.

4.

Manually move the dispatched operation towards the future. What happens to the operations that have not yet been dispatched? _____________________________________________________ _____________________________________________________ Save your plan. a)

Select the operation. Use the mouse to drag it towards a date in the future. The system carries out a midpoint scheduling for the order. Starting from the dispatched operation, the system reschedules the operations that are not dispatched in forward or backward scheduling. Save your plan.

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Lesson Summary You should now be able to: • Name the different options for making resource reservations • Describe the basics and the general process of resource reservation (capacity requirements planning) • Dispatch operations in the capacity planning table of the ECC system • Perform system-aided resource selection in the ECC System

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Lesson: Order Release

Lesson: Order Release Lesson Overview This lesson informs you about the order release function.


Release a process order Explain the order release function Explain the definition and application of a production scheduling profile Describbe the function of system and user statuses

Business Example You will become familiar with the order release function. In this context, you will find out about the definition and application of production scheduling profiles to define business transactions to be executed in parallel. In addition, you will see how you can complement the system status network for process orders by defining user statuses.

Order Release Functions

Figure 61: Order Release Functions

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Process orders have a status management which controls the possible processing sequence of the individual business transactions. When an order is released, the corresponding status is set. The process order must have status Released so that the business transactions for process order execution and process management can be carried out. You can release individual phases and operations, one complete order, or several orders at once. Various activities can be triggered automatically when an order is released: • • • • •

Batch number assignment for the product Batch determination for the material components Material availability check Control recipe creation Inspection lot creation for in-process quality inspections

Customizing: Production Scheduling Profile

Figure 62: Customizing: Production Scheduling Profile

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Customizing: Define Production Scheduling Profiles •

•

In a production scheduling profile, you can specify that particular business transactions are carried out in parallel in a process order, for example: – Order release on order creation – Control recipe creation on order release – Scheduling on order release For batch management, you can specify the following: –

• •

Whether a batch is automatically created for the product on order creation or order release – Whether and how a batch is to be classified You can assign a production scheduling profile to a material and/or production scheduler. The assignment to the material has a higher priority. The production scheduling profile is taken over to the process order when you create the order.

System Statuses and User Statuses: Example

Figure 63: System Statuses and User Statuses: Example

Statuses control which business transactions are permitted for an order. Two different types of statuses are available: system statuses and user statuses A system status is an internal status set by the system. It it set or deleted by a business transaction but not by a user status.

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System statuses follow a fixed sequence. The system status network cannot be influenced by the user. You can log status changes. To do so, you must activate change document creation for the corresponding order type. User statuses complement status management by the system. They are defined by the users according to their needs. User statuses can be set and withdrawn by business transactions. User statuses are linked to orders by a status profile defined in Customizing.

Shop Floor Papers (Standard Lists)

Figure 64: Shop Floor Papers (Standard Lists)

A number of different lists are offered in the standard system. For each order, a maximum of 20 lists may be called up.

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Exercise 26: Statuses and Business Transactions Exercise Objectives After completing this exercise, you will be able to: • Describe how to influence the business transactions in a process order by assigning the statuses Created and Released

Business Example You will examine how the business transactions in a process order are influenced by the system statuses Created and Released.

Task: 1.

Create a process order of order type PO## for material T-HTB1## in plant 1100. Enter 100 000 g as the production quantity and any basic start date.

2.

Display the process order status. Which system statuses are set when you create a process order? _____________________________________________________ _____________________________________________________ _____________________________________________________

3.

Display how the present order status influences the business transactions. In particular, check whether the following transactions are allowed or not allowed at the present status Created: Operation

Influence

Schedule order Release Determine costs Check material availability Confirm order Create control recipe Goods movement Continued on next page

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Display the transaction analysis for some of the transactions. 4.

Release the process order. Which new statuses have been set during order release? _____________________________________________________ _____________________________________________________

5.

Display the business transactions again. In particular, check how the present status Released influences the following transactions: Operation

Influence

Schedule order Determine costs Check material availability Confirm order Create control recipe Goods movement Display the transaction analysis for some of the transactions.

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Solution 26: Statuses and Business Transactions Task: 1.

Create a process order of order type PO## for material T-HTB1## in plant 1100. Enter 100 000 g as the production quantity and any basic start date. a)

Logistics → Production - Process → Process Order → Process Order → Create → With Material Material number:

T-HTB1##

Production plant:

1100

Process order type:

PO##


100 000 g

Start:


Enter 2.

Display the process order status. Which system statuses are set when you create a process order? _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Choose the Status icon for the status line of the order header. The Change Status screen appears. CRTD

Created

SETC

Settlement rule entered

BCRQ

Order to be handled in batches

MANC

Mat. availability not checked

PRC

Pre-costed (after order is saved) Continued on next page

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Display how the present order status influences the business transactions. In particular, check whether the following transactions are allowed or not allowed at the present status Created: Operation

Influence

Schedule order Release Determine costs Check material availability Confirm order Create control recipe Goods movement Display the transaction analysis for some of the transactions. a)

Choose the Business processes tab on the Change Status screen. Operation

Influence

Schedule order

Allowed (= green traffic light)

Release

Allowed

Determine costs

Allowed

Check material availability

Allowed

Confirm order

Not allowed

Create control recipe

Not allowed

Goods movement

Not allowed

To analyze a business transaction, select the relevant transaction and choose Transaction analysis. 4.

Release the process order. Which new statuses have been set during order release? _____________________________________________________


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_____________________________________________________ a)

5.

Choose the Release icon. REL

Released

MACM

Material committed

Display the business transactions again. In particular, check how the present status Released influences the following transactions: Operation

Influence

Schedule order Determine costs Check material availability Confirm order Create control recipe Goods movement Display the transaction analysis for some of the transactions. a)

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Choose the Business processes tab on the Change Status screen. Operation

Influence

Schedule order

Allowed (= green traffic light)

Determine costs

Allowed

Check material availability

Allowed

Confirm order

Allowed

Create control recipe

Allowed

Goods movement

Allowed


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Exercise 27: Production Scheduling Profile Exercise Objectives After completing this exercise, you will be able to: • Describe the function of a production scheduling profile • Define a production scheduling profile in Customizing • Assign a production scheduling profile to a material • Check the activation of the automatic batch number assignment • Set and check the automatic release, control recipe creation, and batch creation at order creation

Business Example You will define a production scheduling profile in Customizing. This profile will determine, for example, that an order is automatically released after it has been created and that control recipes are automatically created after the order has been released. You will assign the production scheduling profile to a material and create a process order for this material to test the profile's functions.

Task 1: 1.

Describe the function of a production scheduling profile. __________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: 1.

Define production scheduling profile GR## in Customizing for plant 1100.

2.

Make the profile settings as described in the following: Specify that an order is automatically released after creation.


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3.

Specify that you want the system to automatically create all control recipes when the order is released.

4.

Specify that you want the system to automatically create a batch master record for the product you want to manufacture when you create an order.

5.

Specify that you do not want the system to update surpluses or deficits by confirmations.

6.

Specify that your order type PO## is set as the default for make-to-stock production.

7.

If required, use field help (F1) to display information on the meaning and function of the various indicators of the production scheduling profile. Save your production scheduling profile. Enter Production scheduling profile grp ## as the description of the profile in the overview screen for production scheduling profiles.

Task 3: 1.

Assign your production scheduling profile GR## to your material T-HTB1## on the Work Scheduling view of plant 1100.

Task 4: 1.

Make sure that automatic batch number assignment has been activated in Customizing for Batch Management.

Task 5: 1.

Create a planned order for material T-HTB1## in MRP area 1100. Use planned order profile LA Stock order. Enter 100 000 g as the order quantity. Enter Today + 2 weeks as the basic finish date. Save the planned order.

2.

Convert your planned order to a process order. Use collective conversion. Enter planning plant 1100 and your MRP controller S## as the criteria for planned order selection. Use process order type PO## for conversion. Continued on next page

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3.

Display your new process order after conversion. Which activities did the system carry out automatically after the process order was created? To answer this question, display the order statuses, the data on the Goods receipt tab, and the material list. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________

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Solution 27: Production Scheduling Profile Task 1: 1.

Describe the function of a production scheduling profile. __________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the function of a production scheduling profile, see the page “Customizing: Production scheduling profile” in your participant handbook.

Task 2: 1.

Define production scheduling profile GR## in Customizing for plant 1100. a)

Customizing: Production Planning for Process Industries → Process Order → Master Data → Define Production Scheduling Profiles Choose New Entries.

2.

Plant:

1100

ProdProfile:

GR##

Make the profile settings as described in the following: Specify that an order is automatically released after creation. a)

At creation X Release

3.

Specify that you want the system to automatically create all control recipes when the order is released. a)

On release X Create control recipe


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4.

Specify that you want the system to automatically create a batch master record for the product you want to manufacture when you create an order. a)

Batch management Autom. batch creation: Autom. batch creation at order creation

5.

Specify that you do not want the system to update surpluses or deficits by confirmations. a)

Confirmation X No update of surplus X No update of deficit

6.

Specify that your order type PO## is set as the default for make-to-stock production. a)

Order type Make-to-stock production: PO##

7.

If required, use field help (F1) to display information on the meaning and function of the various indicators of the production scheduling profile. Save your production scheduling profile. Enter Production scheduling profile grp ## as the description of the profile in the overview screen for production scheduling profiles. a)

Save your production scheduling profile. Choose Back. The system takes you back to the overview screen for production scheduling profiles. You can enter the profile description Production scheduling profile grp ##.


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Task 3: 1.

Assign your production scheduling profile GR## to your material T-HTB1## on the Work Scheduling view of plant 1100. a)

Logistics → Production - Process → Master Data → Material Master → Material → Change → Immediately Material:

T-HTB1##

Enter Choose Work scheduling. Enter Go to plant 1100. Enter If a profile has already been stored, replace it with your new Production scheduling profile:

GR##

Save the material master record.

Task 4: 1.

Make sure that automatic batch number assignment has been activated in Customizing for Batch Management. a)

Customizing: Logistics - General → Batch Management → Batch Number Assignment → Activate Internal Batch Number Assignment Choose Activate Batch Number Assignment. X Automatic batch number assignment active

Task 5: 1.

Create a planned order for material T-HTB1## in MRP area 1100. Use planned order profile LA Stock order. Enter 100 000 g as the order quantity. Continued on next page

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Enter Today + 2 weeks as the basic finish date. Save the planned order. a)

Logistics → Production-Process → MRP → Planned Order → Create Planned order profile: LA Enter Material:

T-HTB1##

MRP area:

1100

Order quantity:

100 000

Finish:

Today +2 weeks

Save your planned order. 2.

Convert your planned order to a process order. Use collective conversion. Enter planning plant 1100 and your MRP controller S## as the criteria for planned order selection. Use process order type PO## for conversion. a)

(…) → MRP → Planned Order → Convert to Proc.Ord. → Collective Conversion Planning plant:

1100

MRP controller:

S##

Process order type:

PO##

Choose the Execute selections icon. The Collective Conversion of Planned Orders: List screen appears. In accordance with the selection criteria you have entered, the system only displays your planned order for material T-HTB1##. Select the line for the planned order in the list and choose Convert. The system converts the planned order to a process order. Choose Back to exit the list. 3.

Display your new process order after conversion. Which activities did the system carry out automatically after the process order was created? Continued on next page

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To answer this question, display the order statuses, the data on the Goods receipt tab, and the material list. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Logistics → Production - Process → Process Order → Process Order → Display Process order: Order number from exercise 5-2 After creating the process order, the system automatically carried out the following activities: Order release: See status REL “Released” Material availability check: See status MACM “Material committed” Control recipe creation: See status CRCR “Control recipe created” Creation of batch master record for product T-HTB1##: See status BASC “Batch assignment complete”, see automatically created batch number in tab page Goods receipt in the order header Batch determination for material components T-RTA## and T-RTB##: See automatically assigned batches in the material list

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Exercise 28: System Statuses and User Statuses Exercise Objectives After completing this exercise, you will be able to: • Describe the function of the system and user statuses • Define a user status profile in Customizing • Assign the user status profile to an order type • Perform order processing using user statuses • Evaluate change documents for status changes in the process order

Business Example You will analyze a user status profile in Customizing. You will assign this status profile to your order type PO##. You will test the status profile function in process order processing and analyze the change documents created for status changes.

Task 1: 1.

Describe the functions of system statuses and user statuses. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: 1.

In the order type-dependent parameters for plant 1100 and order type PO##, define that change documents are written for status changes to the order header, order operations, and material components.


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Task 3: 1.

Display the user status profiles defined in Customizing. In particular, check the settings made for status profile PI_CRP Capacity Req. Pl. Process Ord.

2.

For which object type may the status profile be used? _____________________________________________________

3.

Which user statuses have been defined for the profile? Write down the following: Status No.

4.

Status

Short text

Initial status

Display transaction control for the user statuses CAPA and PLAN. Write down the following: Status CAPA Business transaction

Influence

Status PLAN Business transaction

Influence

Task 4: 1.

Assign status profile PI_CRP to your order type PO## in Customizing.


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Task 5: 1.

Create a process order of order type PO## for material T-HTB1## in plant 1100. Enter 100 000 g as the order quantity and any basic start date.

2.

Which message does the system issue on status processing Release? ______________________________________________________

3.

Display the status information for the message. Why can the order not be released? _____________________________________________________

4.

Display the release log.

5.

Note:In our scenario, the capacity planner responsible for the order must carry out capacity requirements planning for the order. He or she has a special authorization to set the PLAN status in the order afterwards. Set the user status PLAN; Cap.Req.Pl. confirmed.

6.

Try to release the order. Can you release the order now? _____________________________________________________ Save the order.

Task 6: 1.

Display your order once again.

2.

Display the list of all change documents created for status changes.

3.

Display all changes and write down the following for statuses PLAN, CAPA, REL, and CRTD: User status

Action

Date

Time

User

Action

Date

Time

User

PLAN CAPA System status


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Action

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Date

Time

User

CRTD REL

Task 7: 1.

340

To carry out the following exercises, withdraw the assignment of status profile PI_CRP to order type PO## in Customizing.


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Solution 28: System Statuses and User Statuses Task 1: 1.

Describe the functions of system statuses and user statuses. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the functions of system statuses and user statuses, see the page “System Statuses and User Statuses: Example” in your participant handbook.

Task 2: 1.

In the order type-dependent parameters for plant 1100 and order type PO##, define that change documents are written for status changes to the order header, order operations, and material components. a)

Customizing: (…) → Process Order → Master Data → Order → Define Order Type-Dependent Parameters Double-click on the line for plant 1100 and order type PO##. The “Change View ”"Order Type-Dependent Parameters": Details screen appears. Choose the Implementation tab. Status Change Documents: X Header X Operation X Material Save the new entries for the order-type dependent parameters.


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Task 3: 1.

Display the user status profiles defined in Customizing. In particular, check the settings made for status profile PI_CRP Capacity Req. Pl. Process Ord. a)

2.

Customizing: (…) → Process Order → Master Data → Order → Define Status Profiles

For which object type may the status profile be used? _____________________________________________________ a)

Position the cursor on status profile PI_CRP and choose Goto → Object types. X Process order

3.

Which user statuses have been defined for the profile? Write down the following: Status No.

a)

4.

Status

Short text

Initial status

Choose Goto → User status or press User status. Status No.

Status

Short text

Initial status

1

CAPA

Cap.Req.Pl. required

X

2

PLAN

Cap.Req.Pl. confirmed

Display transaction control for the user statuses CAPA and PLAN. Write down the following: Status CAPA Business transaction

Influence


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a)

Influence

Position the cursor on the relevant status and choose Goto → Business transaction control. Status CAPA Business transaction

Influence

Partially release order

Disallowed

Release

Disallowed

Release operation

Disallowed


Influence

Partially release order

Allowed

Release

Allowed

Release operation

Allowed

Task 4: 1.

Assign status profile PI_CRP to your order type PO## in Customizing. a)

Customizing: (…) → Process Order → Master Data → Order → Define Order Types Double-click on your order type PO##. Status profile: PI_CRP Save the new entry for the order type.

Task 5: 1.

Create a process order of order type PO## for material T-HTB1## in plant 1100. Continued on next page

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T-HTB1##

Production plant:

1100

Process order type:

PO##

Enter Total qty:

100 000 g

Start:


Enter 2.

Which message does the system issue on status processing Release? ______________________________________________________ a)

3.

The system issues the following message with regard to order release: The business transaction cannot be carried out.

Display the status information for the message. Why can the order not be released? _____________________________________________________ a)

Choose Status information. The following message is displayed: User status CAPA is active.

4.

Display the release log. a)

5.

Goto → Logs → On release

Note:In our scenario, the capacity planner responsible for the order must carry out capacity requirements planning for the order. He or she has a special authorization to set the PLAN status in the order afterwards. Set the user status PLAN; Cap.Req.Pl. confirmed. a)

Choose the Status icon in the order header. Set the user status PLAN, Cap.Req.Pl. confirmed on the Change Status screen. Choose Back to exit the Change Status screen.

6.

Try to release the order. Continued on next page

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Can you release the order now? _____________________________________________________ Save the order. a)

Choose the Release icon After you have set the PLAN user status, you can release the process order.

Task 6: 1.

Display your order once again. a)

2.

(…) → Process Order → Display

Display the list of all change documents created for status changes. a)

Choose the Status icon in the order header. On the Change Status screen, choose: Extras → Change Documents → All.

3.

Display all changes and write down the following for statuses PLAN, CAPA, REL, and CRTD: User status

Action

Date

Time

User

Action

Date

Time

User

PLAN CAPA System status


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User status

Action

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Date

Time

User

CRTD REL a)

On the Change Documents in Status Management screen, choose All changes. User status

Action

PLAN

Active

CAPA

Inactive

Date

Time

User

Date

Time

User

Active System status

Action

CRTD

Inactive Active

REL

Active

Task 7: 1.

To carry out the following exercises, withdraw the assignment of status profile PI_CRP to order type PO## in Customizing. a)

Customizing: (…) → Process Order → Master Data → Order → Define Order Types Double-click on your order type PO##. Delete the entry PI_CRP in the Status profile field and save the order type.

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Lesson Summary You should now be able to: • Release a process order • Explain the order release function • Explain the definition and application of a production scheduling profile • Describbe the function of system and user statuses

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Unit Summary

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Unit Summary You should now be able to: • List the range of activities in process planning. • Name the Customizing settings required for material availability checks • Explain the functions of the material availability check and carry them out in the system • Explain the Customizing settings for batch determination • Create a batch search strategy • Make the appropriate settings for batch determination in the material master records of your material components • Carry out batch determination for your process order • Carry out a sample scenario on how to use the functions of batch determination, active ingredient management, and material quantity calculation together. • Name the different options for making resource reservations • Describe the basics and the general process of resource reservation (capacity requirements planning) • Dispatch operations in the capacity planning table of the ECC system • Perform system-aided resource selection in the ECC System • Release a process order • Explain the order release function • Explain the definition and application of a production scheduling profile • Describbe the function of system and user statuses

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Test Your Knowledge

Test Your Knowledge

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1.

Name the main activities of process planning.

2.

How can you trigger a material availability check?

3.

Which application-specific master record is used to determine the batch determination process.

4.

What is the material quantity calculation for?

5.

Which methods can be used to reserve resources with SAP?

6.

Name a number of activities that are only possible after the order is released.


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Answers 1.

Name the main activities of process planning. Answer: • • • • • •

2.

Order creation Batch number assignment Resource/line reservation Batch determination Material quantity calculation Material availability check

How can you trigger a material availability check? Answer: Automatically • During order creation • During order release Manually at any time • • •

3.

In mass processing for a number of orders For an entire order For individual components of an order

Which application-specific master record is used to determine the batch determination process. Answer: It is defined using a batch search strategy.

4.

What is the material quantity calculation for? Answer: In material quantity calculation, you can determine the material quantities to be used or obtained in a production process, taking into account the mixing ratios of the input materials, yield ratios of the products and the specific batch attributes. You can also determine the phase quantities.

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Test Your Knowledge

5.

Which methods can be used to reserve resources with SAP? Answer: Capacity requirements planning with SAP ECC • Tabular planning tables • Graphical planning tables • Mass planning in the background Detailed scheduling with SAP SCM(APO) • • • •

6.

Simultaneous material and capacity requirements planning DS planning board (continuous with regard to time) Product planning table (period-oriented) Planning optimization, production campaigns

Name a number of activities that are only possible after the order is released. Answer: • • • • •

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Printing documents (order documents) Creating control recipes for the order Posting material withdrawals for the order Posting order confirmations Posting goods receipts for the order


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Unit 5 Principle of Process Management (I) Unit Overview Topics: • • • • • • •

Principle of process management Creating and sending control recipes Control recipe monitor PI sheet Postings for process orders Flexible data entry with process messages Message monitor

Unit Objectives After completing this unit, you will be able to: •

Describe the principle of process management

Unit Contents Lesson: Principle of Process Management (I) ..............................354

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Unit 5: Principle of Process Management (I)

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Lesson: Principle of Process Management (I) Lesson Overview This lesson gives you an initial overview of the principle of process management.


Describe the principle of process management

Business Example The production in your company is controlled automatically through process control systems, partially automatically, or manually, depending on the area. You want to use the ECC Process Management for process control, so you first get an overview of the basic principles.

Process Management Figure 65: Process Management

Process management is the interface between PP-PI and the systems involved in process control. Due to its flexible structure, it can be linked to fully automated, partially automated, as well as manually operated lines. Process management includes the following functions: •

• •

•

Receiving control recipes with process instructions from released process orders. The process instructions define, for example, the process steps to be executed and the process data to be confirmed (using process messages) in detail. Sending control recipes to the corresponding process operators or process control systems Manual processing: Displaying control recipes in natural language in the form of PI sheets that can be displayed and maintained on the screen by the process operator Receiving, checking, and sending process messages with actual process data from the process control system or the PI sheet

Data is exchanged with process control systems using the PI-PCS interface.

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Lesson: Principle of Process Management (I)

Creating and Sending Control Recipes: Alternative 1 Figure 66: Creating and Sending Control Recipes: Alternative 1

Alternative 1: Maintaining process instructions for the phases • •

You can define information relevant for process control in the process order in the form of process instructions for the phases of the order. The process management groups the process instructions to control recipes and transfers these to the control recipe destinations assigned to the phases.

Creating and Sending Control Recipes: Alternative 2 Figure 67: Creating and Sending Control Recipes: Alternative 2

Alternative 2: Maintaining process instructions for XSteps •

From SAP R/3 ERP and SCM Extension 2.00 (EA_APPL_2.00), the data for the process management can alternatively be maintained in the form of XSteps (execution steps). Using XSteps enables you to maintain process instructions in the form of reusable and referenceable modules. A Standard XStep Repository with version management is available.

Control Recipe Monitor Figure 68: Control Recipe Monitor

The control recipe monitor provides information on the current processing status of a control recipe. From the monitor, you can call up different logs containing more detailed information on the individual process steps carried out and the errors that occurred during control recipe processing. On the basis of this information, you can carry out the following transactions from within the monitor: • •

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Send control recipes if they are not automatically sent by a background job defined in Customizing. Delete control recipes


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HTML-Based PI Sheet (I) Figure 69: HTML-Based PI Sheet (I)

The SAP PI sheet provides for processing on the screen, which means the process operator is to enter, confirm, or complete data interactively. Depending on the process instructions contained in a control recipe, the PI sheet has the following elements and functions, for example: • • • • • • • •

Display of information on process (control instructions, notes, and so on) Input fields and tables for entering process data, input validations, signatures Batch determination and batch check Process data calculation Reading and writing data from internal or external applications Link to QM inspection results recording Sequence definition for determining the processing sequence of phases Comments on documentation and messages from process events

As of Release 4.6C, you can generate PI sheets in HTML. The browser-based PI sheet enhances the ABAP list-based PI sheet. It gives you the advantage of a flexible, user-specific layout definition and allows you to define frames, for example, for linking to documents, graphics, the Internet and intranet.

HTML-Based PI Sheet (II) Figure 70: HTML-Based PI Sheet (II)

Standard Postings for Process Orders Figure 71: Standard Postings for Process Orders

The standard postings for process orders (goods issue, confirmation, goods receipt) can be performed using manual data entry in the ECC System or process messages from a PI sheet or a process control system. The process instructions of the control recipe for an order define which process messages are requested by a PI sheet or a process control system. Confirmations are entered for phases and secondary resources (however, not for operations). The simplest confirmation procedure is the confirmation for the process order.

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Flexible Data Entry with Process Messages Figure 72: Flexible Data Entry with Process Messages

Process messages are data structures with which actual data for a process is confirmed from process control to one or more destinations. You can define process messages in Customizing according to your own specific requirements. The standard SAP System contains a number of predefined message categories enabling you to transfer current data from process control to the ECC System. The process messages are first sent to the process management. They are then checked and forwarded to pre-defined destinations.

Message Monitor Figure 73: Message Monitor

The message monitor provides information on the current processing status of process messages. From the monitor, you can call up various logs containing more detailed information on the processing of individual messages and errors that occurred. On the basis of this information, you can carry out the following transactions from within the monitor: • • •

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Complete or correct messages Send messages if they are not automatically sent by a background job defined in Customizing Delete messages


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Principle of Process Management: Topic Summary • • • • • •

358

Process management coordinates the transfer of data between the ECC System and the process control level. Due to its flexible structure, process management can be linked to automated, partially automated, and manually operated lines. After a process order has been released for production, the process instructions maintained in the process order are grouped into control recipes. Control recipes are either transferred to process control systems via the PCS interface or they are displayed for process operators in the form of a PI sheet. Control recipes are either transferred to process control systems via the PCS interface or they are displayed for process operators in the form of a PI sheet. In return, process management receives process messages from the process control level and transfers them to the various message destinations.


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Lesson Summary You should now be able to: • Describe the principle of process management

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Unit Summary

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Unit Summary You should now be able to: • Describe the principle of process management

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Test Your Knowledge

Test Your Knowledge 1.

2005/Q2

Try to summarize the principle of process management


361

Test Your Knowledge

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Answers 1.

Try to summarize the principle of process management Answer: • • •

•

• •

362

Process management coordinates the transfer of data between the ECC System and the process control level. Due to its flexible structure, process management can be linked to automated, partially automated, and manually operated lines. After a process order has been released for production, the process instructions maintained in the process order are grouped into control recipes. Control recipes are either transferred to process control systems via the PCS interface or they are displayed for process operators in the form of a PI sheet. In the PI sheet, the process instructions are displayed in natural language on the screen. In return, process management receives process messages from the process control level and transfers them to the various message destinations.


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Unit 6 Material Staging and Withdrawal Unit Overview Topics: • • •

Options for material staging Manual goods issue posting Goods issue posting using process messages

Unit Objectives After completing this unit, you will be able to: • • •

Name the possible material staging procedures Perform goods issue postings for process orders manually using the corresponding ECC transactions Perform goods issue postings for process orders manually using process messages from the PI sheet

Unit Contents Lesson: Material Staging Options ............................................364 Exercise 29: Material Staging Options ..................................367 Lesson: Goods Issue Posting .................................................372 Exercise 30: Goods Issue Posting .......................................375

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SCM340

Lesson: Material Staging Options Lesson Overview This lesson provides you with an overview of the possible procedures for material staging.


Name the possible material staging procedures

Business Example You will become familiar with the representation of the possible procedures for performing material staging for process orders.

The Material Staging Process (I)

Figure 74: The Material Staging Process (I)

The ECC System has various procedures for controlling material staging.The procedures are • • •

364

a) Warehouse management using the component MM-IM (Inventory Management) b) Replenishment control using the component Kanban c) Storage location management and replenishment control using the component MM-WM (Warehouse Management System)


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Lesson: Material Staging Options

The Material Staging Process (II)

Figure 75: The Material Staging Process (II)

The basis for material withdrawal for process orders are material withdrawal slips, pull lists, pick lists and similar documents, as well as PI sheets and weighing systems linked via the PI-PCS interface. The Warehouse Management System has three options, which are described below: •

Pick list items are provided for the process order in exactly the same quantity as the requirements quantity. These parts can be provided for the process order at a physical storage location or dynamic storage location (process order). Here, you can create transfer requirements manually or automatically when you release the order.

• •

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Crate parts are requested manually when a container is almost empty. Release order parts are requested manually. The required quantity is calculated using the target quantities of the components in the selected released orders. Thereby, the stock situation is taken into account in the production and the replenishment storage types.


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Exercise 29: Material Staging Options Exercise Objectives After completing this exercise, you will be able to: • Name the options for material staging • Put together a pick list

Business Example Material components must be staged for production on a specific date and in a specific quantity. There are different procedures for material staging. You will become familiar with the different procedures for material staging. As an example, you will create a pick list for an order to withdraw the required materials from the warehouse and post the relevant goods issue.

Task: 1.

Use the information in your participant handbook to get an overview of the different procedures for material staging. Notes: _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________

2.

In the Introduction unit, you released an order for the production of material T-FI1##. Use the mass processing function (component list) to create a pick list for the order to stage the material components in the warehouse. On the Mass processing for process orders screen, choose: Continued on next page

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List:

Components

Profile:

Picking profile

In the Selection tab page, choose: Material:

T-FI1##

Sys. status:

REL

In the Mass processing tab page, choose: Function:

Pick

Execute Function:

Execute function in dialog

Processing mode:

Execute goods movement in dialog

Finally, execute the program. A list with the components for the order appears. Select all material components and then execute the mass processing: A picking list with all reservation items to be picked appears. Note that you can still change the data in the list. In particular, note the Batch determination option in the list. Note that you can record an unplanned goods issue. Note that you can print the list. Select all components and save. The goods issue postings for the material components are made. 3.

If required, you can now analyze the data updates that the goods issue postings triggered (for example, in the order information system, in the order, and in inventory management). Note: Data update will be dealt with in more detail in the following exercises.

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Solution 29: Material Staging Options Task: 1.

Use the information in your participant handbook to get an overview of the different procedures for material staging. Notes: _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ a)

2.

For more information, see to the pages “The Material Staging Process (I), (II)” in your participant handbook.

In the Introduction unit, you released an order for the production of material T-FI1##. Use the mass processing function (component list) to create a pick list for the order to stage the material components in the warehouse. On the Mass processing for process orders screen, choose: List:

Components

Profile:

Picking profile

In the Selection tab page, choose: Material:

T-FI1##

Sys. status:

REL

In the Mass processing tab page, choose:


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Function:

Pick

Execute Function:

Execute function in dialog

Processing mode:

Execute goods movement in dialog

Finally, execute the program. A list with the components for the order appears. Select all material components and then execute the mass processing: A picking list with all reservation items to be picked appears. Note that you can still change the data in the list. In particular, note the Batch determination option in the list. Note that you can record an unplanned goods issue. Note that you can print the list. Select all components and save. The goods issue postings for the material components are made. a) 3.

Logistics → Production-Process → Process Order → Tools → Mass Processing

If required, you can now analyze the data updates that the goods issue postings triggered (for example, in the order information system, in the order, and in inventory management). Note: Data update will be dealt with in more detail in the following exercises. a)

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See exercise


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Lesson Summary You should now be able to: • Name the possible material staging procedures

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Lesson: Goods Issue Posting Lesson Overview This lesson informs you about the goods issue posting for process orders.


Perform goods issue postings for process orders manually using the corresponding ECC transactions Perform goods issue postings for process orders manually using process messages from the PI sheet

Business Example You will test goods receipt posting for process orders. Since not all areas in your company use the functions of process management, you must become familiar with both inventory postings using process messages and manual postings using the corresponding ECC transactions.

Material Withdrawal (Goods Issue) Figure 76: Material Withdrawal (Goods Issue)

The material components required for production are withdrawn from the warehouse as goods issues. The delivery of the material produced to the warehouse is recorded in the form of goods receipts. Both goods movements trigger the following activities in the system: • • • •

372

The system creates a material document that describes the goods movement from the materials management point of view. The system creates an accounting document describing the material movement from the accounting point of view. The system updates the material's stock quantities. The system updates the stock values in the material master as well as the material stock and consumption accounts.


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Lesson: Goods Issue Posting

Goods Issue Figure 77: Goods Issue

You can post material receipts manually by using the corresponding ECC transactions or by sending process messages from the PI sheet or a process control system. When you create a process order, the system automatically creates a reservation for the material components required for the order. Each material component of the order is given an item number within the reservation. You can carry out planned goods issues (that is, for the reservation items) and unplanned goods issues. Planned goods issues reduce the reservation. For unplanned withdrawals, the system only updates costs. You can also post goods issues automatically during confirmation (backflushing). You can use backflushing, for example, if you do not want to physically issue a material from the warehouse with reference to an order. The system assumes that the material is staged at the corresponding work center.

Goods Issue Using a Process Message: Example Figure 78: Goods Issue Using a Process Message: Example

You can use process messages to trigger goods issue postings from a process control system or the PI sheet. The graphic shows a goods issue posting from a PI sheet. In our example, a process message of category PI_CONS to post a goods issue is created when the quantity of ammonia charged is entered in the PI sheet. The message is sent to the corresponding message destination. The message destination of message category PI_CONS is the Goods Issue Posting function module.

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Exercise 30: Goods Issue Posting Exercise Objectives After completing this exercise, you will be able to: • Perform goods issue posting manually • Differentiate between planned and unplanned withdrawals • Perform goods issue posting using process messages

Business Example You will test different scenarios for goods issue postings for process orders. You will perform manual goods issue postings. For example, a process operator/worker takes the material withdrawal slip to the warehouse, withdraws the material or materials, and posts the goods issue with reference to the material withdrawal slip. You will post goods issues by maintaining the PI sheet. A process operator can, for example, enter process events directly in the PI sheet in ECC and thus report them using process messages.

Task 1: 1.

Name the different ways in which goods issues can be entered for process orders. Which business transactions are triggered by a goods issue posting? Notes: _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________


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Task 2: 1.

In the order type-dependent parameters for plant 1100 and order type PO##, specify that the following goods movements must be documented: • Goods receipts for the order • Planned goods issues for the reservation • Unplanned goods issues for the order In the Goods Movements field, enter the Standard Profile for the evaluation of documented goods movements in the order info system.

Task 3: Manual goods issue posting 1.

Create a process order of order type PO## for material T-FF9## in plant 1100. Enter 1,000 L as the quantity to be produced. Enter today's date as the basic start date.

2.

Make sure that the order was automatically released after order creation.

3.

Save the order and write down the order number: ______________________________________________________

Task 4: 1.

Display the process order.

2.

Display the material list. Write down the material list items along with the phases to which they are assigned: Itm

Material

Reqrd. qty

Batch

0010

-------

0020

-------

0030

-------

Phase

0040 3.

Display the General Data for material components T-RF7##, T-RF9##, and for the batch single record for component T-RF8##. Continued on next page

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Write down the requirements quantities, issue quantities, reservation quantities, and reservation items: Reqmts quantity

Committed qty

Reservation

T-RF7## T-RF9## T-RF8## B1001 4.

Display the stock/requirements list for the material components. Write down the first two lines for each material component: T-RF7## Date

MRP element

MRP element data

Recpt/Reqd qty

Available quantity

MRP element

MRP element data

Recpt/Reqd qty

Available quantity

MRP element

MRP element data

Recpt/Reqd qty

Available quantity

T-RF9## Date

T-RF8## Date

Task 5: 1.

Post a material withdrawal for material component T-RF7## for the order from exercise 3. Continued on next page

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2.

SCM340

Withdraw the material from storage location 0002 in plant 1100. Enter the goods issue with reference to the reservation.

3.

The system proposes the quantity to be withdrawn according to the plan. Accept the quantity that the system proposes and save the goods issue posting.

4.

Display the General Data for material component T-RF7## in your process order. Write down the following: Reqmts quantity

5.

Committed qty

Final issue

What does the Final issue indicator mean? Use the field help (F1) to answer this question. ______________________________________________________ ______________________________________________________ Why has this indicator been set? ______________________________________________________

6.

Display the current stock/requirements list for material T-RF7##. What do you notice? ______________________________________________________

7.

Post an additional material withdrawal of 50 L for component T-RF7##. Withdraw the material from storage location 0002 in plant 1100. Enter the goods issue with reference to the reservation. Since the final issue indicator has been set for the reservation item, you must set the Suggest zero lines indicator on the initial screen. On the selection screen for the goods issue, enter a quantity of 50 L to be withdrawn and save your goods issue.

8.

Again, display the General Data for your material component T-RF7## in your process order. Write down the following:


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Reqmts quantity

9.

Committed qty

Final issue

Display the costs incurred by the order. Note that there is an actual costs update with regard to the goods issues.

Task 6: 1.

Post a partial issue of material component T-RF9## for your current order.

2.


3.

The system proposes the quantity to be withdrawn according to the plan. Change the proposed quantity. Only withdraw half of the planned requirements quantity. Save your goods issue posting.

4.


5.

Committed qty

Final issue

Display the stock/requirements list for material T-RF9##. What do you notice? ______________________________________________________ Write down the first two lines: T-RF9## MRP element

MRP element data

Recpt/Reqd qty

Available quantity


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Task 7: 1.

Post another partial issue of material component T-RF9## for the order.

2.


3.

The system proposes the quantity still to be withdrawn according to the plan. Change the proposed quantity. Only withdraw half of the quantity yet to be withdrawn. Furthermore, you want to deviate from the plan and do not want to withdraw further quantities. For this reason, set the final issue indicator FIs when you enter the goods issue. Save your goods issue posting.

4.


5.

Committed qty

Final issue

Display the costs incurred by the order. Note that there is an actual costs update with regard to the goods issues.

6.

Display the stock/requirements list for material T-RF9##. What do you notice? ______________________________________________________

Task 8: 1.

Post an unplanned withdrawal with regard to batch 1-RI5## of material T-RI5##.

2.

Withdraw the material from storage location 0002 in plant 1100. Select movement type 261.

3.

Enter the number of your process order when you enter the goods issue. Post a goods issue quantity of 50 L. Save the goods issue. Continued on next page

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4.

Display the order costs in the process order. Note that there is an actual costs update with regard to the unplanned goods issue.

5.

Display the goods movement list in the process order. Choose layout /SCM340 in the order information system. Write down the following: Material

GMov

Mat. doc.

MvT

SLoc

Batch

You can use input help (F4) to obtain information on the goods movement indicator GMov.

Task 9: Goods issue posting using process messages 1.

Note: The following exercise aims at illustrating goods issue posting using process messages by having you maintain a PI sheet with reference to the master recipe T-RC9#. The process instructions have been created for control recipe destination FI. Therefore, make the following changes in your master recipe:

2.

Replace the control recipe destination assigned to all phases with the new destination FI.

3.

Delete the process instruction FE_PROD in phase 220 Save your recipe.

Task 10: 1.

Create a process order of order type PO## for material T-FF9## in plant 1100. Enter 1000 L as the quantity to be produced. Continued on next page

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Enter Today +1 week as the basic start date. 2.

Make sure that the control recipe was automatically created after order creation.

3.

Save the order and write down the order number: __________________________________________________

Task 11: 1.

Send your control recipe in the control recipe monitor.

Task 12: 1.

Find and maintain the PI sheet. In this scenario, the PI sheet’s only purpose is to record and report quantities consumed. The planned values from the order are set as default values. You can overwrite these values. By executing your signature (with ECC user and ECC password) at the end of the PI sheet, you transfer the process messages containing the material consumption recorded to the message monitor.

Task 13: 1.

Go to the message monitor and analyze the messages of message category PI_CONS that were created while you maintained the PI sheet. Send the messages.

Task 14: 1.


2.

Display the General Data for the material components. Compare the updated issue quantities with your entries in the PI sheet.

3.

382

Display the costs incurred by your order.


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Solution 30: Goods Issue Posting Task 1: 1.

Name the different ways in which goods issues can be entered for process orders. Which business transactions are triggered by a goods issue posting? Notes: _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ a)

For some corresponding information see the page “Goods Issue” in your participant handbook.

Task 2: 1.

In the order type-dependent parameters for plant 1100 and order type PO##, specify that the following goods movements must be documented: • Goods receipts for the order • Planned goods issues for the reservation • Unplanned goods issues for the order


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In the Goods Movements field, enter the Standard Profile for the evaluation of documented goods movements in the order info system. a)

Customizing: (…) → Prozeßauftrag → Stammdaten → Auftrag → Auftragsartabhängige Parameter definieren Double-click on the line for plant 1100 and order type PO##. Choose the Implementation tab. Documentation of goods movements: Goods movements: Standard profile X planned goods issue X unplanned goods issue X goods receipt for process order Save the new entries for the order-type dependent parameters.

Task 3: Manual goods issue posting 1.

Create a process order of order type PO## for material T-FF9## in plant 1100. Enter 1,000 L as the quantity to be produced. Enter today's date as the basic start date. a)


T-FF9##

Production plant:

1100

Process order type:

PO##

Enter Total qty:

1,000 l

Start:

Today

Enter 2.

Make sure that the order was automatically released after order creation. a)

3.

The order status REL must have been set after order creation.

Save the order and write down the order number: Continued on next page

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______________________________________________________ a)

Save the order and write down the order number.

Task 4: 1.

Display the process order. a)

(…)→ Process Order → Display Process order:

2.

Order number

Display the material list. Write down the material list items along with the phases to which they are assigned: Itm

Material

Reqrd. qty

Batch

0010

-------

0020

-------

0030

-------

Phase

0040 a)

3.

Choose Materials. Itm

Material

Reqrd. qty

Batch

Phase

0010

T-RF7##

900

-------

0110

0020

T-RF9##

30

-------

0110

0030

T-RF8##

-------

-------

0210

0040

T-RF8##

70

B1001

0210

Display the General Data for material components T-RF7##, T-RF9##, and for the batch single record for component T-RF8##. Write down the requirements quantities, issue quantities, reservation quantities, and reservation items:


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Reqmts quantity

Committed qty

Reservation

T-RF7## T-RF9## T-RF8## B1001 a)

Double-click the material list item. Reqmts quantity

Committed qty

Reservation

T-RF7##

900

0

Res.no.

Itm

T-RF9##

30

0

Res.no.

Itm

T-RF8##

70

0

Res.no.

Itm

B1001 4.

Display the stock/requirements list for the material components. Write down the first two lines for each material component: T-RF7## Date

MRP element

MRP element data

Recpt/Reqd qty

Available quantity

MRP element

MRP element data

Recpt/Reqd qty

Available quantity

T-RF9## Date


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T-RF8## Date

a)

MRP element

MRP element data

Recpt/Reqd qty

Available quantity

(…) → Process Order → Environment → Stock/Requirements List Material: T-RF7## or T-RF9## or T-RF8## Plant: 1100 Enter T-RF7## MRP element

MRP element data

Recpt/Reqd qty

STOCK

Available quantity 100 000

OrdRes

T-FF9##

900 -

99 100

MRP element data

Recpt/Reqd qty

Available quantity

T-RF9## MRP element STOCK

100 000

OrdRes

T-FF9##

30 -

99 970

MRP element data

Recpt/Reqd qty

Available quantity

T-RF8## MRP element STOCK OrdRes

100 000 T-FF9##

70 -

99 930

Task 5: 1.

Post a material withdrawal for material component T-RF7## for the order from exercise 3. a)

(…) → Process Order → Environment → Material Movement → Withdraw Material Continued on next page

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2.

SCM340

Withdraw the material from storage location 0002 in plant 1100. Enter the goods issue with reference to the reservation. a) Plant:

1100

Storage location:

0002

Choose To Reservation..... Reference: Reservation screen appears. Enter the reservation number and reservation item for material T-RF7## (see exercise 4-3) and choose Enter. 3.

The system proposes the quantity to be withdrawn according to the plan. Accept the quantity that the system proposes and save the goods issue posting. a)

The Enter Goods Issue: Selection Screen appears. The system proposes the quantity to be withdrawn according to the plan. Accept the quantity that the system proposes and save the goods issue posting.

4.


a)

Committed qty

Final issue

(…) Process Order → Display Choose Materials. Double-click the item number for component T-RF7##.

5.

Reqmts quantity

Committed qty

Final issue

900

900

X

What does the Final issue indicator mean? Use the field help (F1) to answer this question. ______________________________________________________ Continued on next page

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______________________________________________________ Why has this indicator been set? ______________________________________________________ a)

Use the field F1 help to display information on the meaning of the final issue indicator. The system automatically sets the final issue indicator when the quantity withdrawn is greater than or equal to the planned quantity.

6.

Display the current stock/requirements list for material T-RF7##. What do you notice? ______________________________________________________ a)

(…) → Process Order → Environment → Stock/Requirements list Material:

T-RF7##

Plant:

1100

The reservation has been totally cleared. The available plant stock has been reduced by the quantity withdrawn. T-RF7## MRP element

MRP element data

Recpt/Reqd qty

STOCK 7.


Post an additional material withdrawal of 50 L for component T-RF7##. Withdraw the material from storage location 0002 in plant 1100. Enter the goods issue with reference to the reservation. Since the final issue indicator has been set for the reservation item, you must set the Suggest zero lines indicator on the initial screen.


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On the selection screen for the goods issue, enter a quantity of 50 L to be withdrawn and save your goods issue. a)

(…) → Process Order → Environment → Material Movement → Withdraw Material Plant:

1100

Storage location:

0002

X

Suggest zero lines

Choose To Reservation..... Reference: Reservation screen appears. Enter the reservation number and reservation item for material T-RF7## (see exercise 4-3) and choose Enter. The Enter Goods Issue: Selection Screen appears. Select the line for material component T-RF7## and enter a quantity of 50 L. Save the goods issue. 8.

Again, display the General Data for your material component T-RF7## in your process order. Write down the following: Reqmts quantity

a)

Committed qty

Final issue


9.

Reqmts quantity

Committed qty

Final issue

900

950

X

Display the costs incurred by the order. Note that there is an actual costs update with regard to the goods issues. a)

Goto → Costs → Analysis Due to the goods issue of material T-RF7## for the order, the corresponding actual costs have been updated. Continued on next page

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Task 6: 1.

Post a partial issue of material component T-RF9## for your current order. a)

2.

(…) → Process Order → Environment → Material Movement → Withdraw Material


1100

Storage location:

0002


The system proposes the quantity to be withdrawn according to the plan. Change the proposed quantity. Only withdraw half of the planned requirements quantity. Save your goods issue posting. a)

The system proposes the quantity to be withdrawn according to the plan (30 kg). Change the proposed quantity. Only withdraw half of the planned requirements quantity (15 kg). Save your goods issue posting.

4.

Display the General Data for material component T-RF9## in your process order. Write down the following:


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Reqmts quantity

a)

Committed qty

Final issue


5.

Reqmts quantity

Committed qty

30

15

Final issue

Display the stock/requirements list for material T-RF9##. What do you notice? ______________________________________________________ Write down the first two lines: T-RF9## MRP element

a)

MRP element data

Recpt/Reqd qty

Available quantity


T-RF9##

Plant:

1100

The reservation has been reduced by the quantity withdrawn. The available plant stock has been reduced by the quantity withdrawn. T-RF9## MRP element

MRP element data

Recpt/Reqd qty

STOCK OrdRes


T-FF9##

15-

99 970


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Task 7: 1.

Post another partial issue of material component T-RF9## for the order. a)

2.

(…) → Process Order → Environment → Material Movement → Withdraw Material


1100

Storage location:

0002


The system proposes the quantity still to be withdrawn according to the plan. Change the proposed quantity. Only withdraw half of the quantity yet to be withdrawn. Furthermore, you want to deviate from the plan and do not want to withdraw further quantities. For this reason, set the final issue indicator FIs when you enter the goods issue. Save your goods issue posting. a)

The system proposes the quantity still to be withdrawn according to the plan (15 kg). Change the proposed quantity. Withdraw only half of the quantity still to be withdrawn according to plan (7.5 kg). Set the final issue indicator. X FIs Save your goods issue posting.

4.

Display the General Data for material component T-RF9## in your process order. Write down the following:


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Reqmts quantity

a)

SCM340

Committed qty

Final issue


5.

Reqmts quantity

Committed qty

Final issue

30

22,5

X

Display the costs incurred by the order. Note that there is an actual costs update with regard to the goods issues. a)

6.

Due to the goods issue of material T-RF9## for the order, further actual costs have been updated.

Display the stock/requirements list for material T-RF9##. What do you notice? ______________________________________________________ a)


T-RF9##

Plant:

1100

The reservation has been totally cleared. The available plant stock has been reduced by the quantity withdrawn. T-RF9## MRP element

MRP element data

STOCK

Recpt/Reqd qty

Available quantity 99 977,5

Task 8: 1.

Post an unplanned withdrawal with regard to batch 1-RI5## of material T-RI5##. a)

(…) → Process Order → Environment → Material Movement → Withdraw Material Continued on next page

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2.

Withdraw the material from storage location 0002 in plant 1100. Select movement type 261. a)

3.

Movement type:

261

Plant:

1100

Storage location:

0002

Enter the number of your process order when you enter the goods issue. Post a goods issue quantity of 50 L. Save the goods issue. a)

Choose Enter. The Enter Goods Issue: New Items screen appears. Order:

Order number

Material:

T-RI5##

Quantity:

50

Batch:

1-RI5##

Save the goods issue. 4.

Display the order costs in the process order. Note that there is an actual costs update with regard to the unplanned goods issue. a)

(…) Process Order → Display Goto → Costs → Analysis Due to the goods issue of material T-RF15## for the order, further actual costs have been updated. There are no planned costs for material T-RI5##.

5.

Display the goods movement list in the process order. Choose layout /SCM340 in the order information system. Write down the following:


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Material

SCM340

GMov

Mat. doc.

MvT

SLoc

Batch

You can use input help (F4) to obtain information on the goods movement indicator GMov. a)

On the order header, choose Goto → Lists → Documented Goods Movements In the order information system, choose layout settings... select layout... Layout /SCM340 Material

GMov

Mat. doc.

MvT

SLoc

T-RF7##

1

Doc.no. 261

0002

T-RF7##

1

Doc.no. 261

0002

T-RF9##

1

Doc.no. 261

0002

T-RF9##

1

Doc.no. 261

0002

T-RI5##

2

Doc.no. 261

0002

Batch

1-RI5##

GMov 1 means planned goods issue. GMov 2 means unplanned goods issue.

Task 9: Goods issue posting using process messages 1.

Note: The following exercise aims at illustrating goods issue posting using process messages by having you maintain a PI sheet with reference to the master recipe T-RC9#. The process instructions have been created for control recipe destination FI. Continued on next page

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Therefore, make the following changes in your master recipe: a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Change Recipe group:

2.

Replace the control recipe destination assigned to all phases with the new destination FI. a)

3.

T-RC9##

See description

Delete the process instruction FE_PROD in phase 220 Save your recipe. a)

See description

Task 10: 1.

Create a process order of order type PO## for material T-FF9## in plant 1100. Enter 1000 L as the quantity to be produced. Enter Today +1 week as the basic start date. a)


T-FF9##

Production plant:

1100

Process order type:

PO##


1,000 l

Start:

Today + 1 week

Enter 2.

Make sure that the control recipe was automatically created after order creation. a)

3.

The order status SREZ must have been set after order creation.

Save the order and write down the order number: Continued on next page

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__________________________________________________ a)

See description

Task 11: 1.

Send your control recipe in the control recipe monitor. a)

Logistics → Production - Process → Process Management → Control Recipe → Control Recipe Monitor Process order: Order number

Task 12: 1.

Find and maintain the PI sheet. In this scenario, the PI sheet’s only purpose is to record and report quantities consumed. The planned values from the order are set as default values. You can overwrite these values. By executing your signature (with ECC user and ECC password) at the end of the PI sheet, you transfer the process messages containing the material consumption recorded to the message monitor. a)

Logistics → Production - Process → Process Management → PI Sheet → Find

Task 13: 1.

Go to the message monitor and analyze the messages of message category PI_CONS that were created while you maintained the PI sheet.


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Send the messages. a)

Logistics → Production - Process → Process Management → Message → Message Monitor Process order: Order number Choose Enter. The Process Message Monitor: Messages screen appears. By double-clicking a message you can display the message characteristics. Send the messages.

Task 14: 1.


2.


Display the General Data for the material components. Compare the updated issue quantities with your entries in the PI sheet. a)

Choose Materials. Double-click on the item number

3.

Display the costs incurred by your order. a)

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Goto → Costs → Analysis


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Lesson Summary You should now be able to: • Perform goods issue postings for process orders manually using the corresponding ECC transactions • Perform goods issue postings for process orders manually using process messages from the PI sheet

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Unit Summary

Unit Summary You should now be able to: • Name the possible material staging procedures • Perform goods issue postings for process orders manually using the corresponding ECC transactions • Perform goods issue postings for process orders manually using process messages from the PI sheet

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Unit Summary

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Test Your Knowledge

Test Your Knowledge

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1.

What components can be used to control a material staging process with SAP?

2.

Which of the following activities are connected to a goods issue posting for an order?


403

Test Your Knowledge

SCM340

Answers 1.

What components can be used to control a material staging process with SAP? Answer: • • •

2.

Warehouse management using the component MM-IM (Inventory Management) Replenishment control using the component Kanban Storage location management and replenishment control using the component MM-WM (Warehouse Management System)

Which of the following activities are connected to a goods issue posting for an order? Answer: • • • •

404

Update of the stock quantity Update of the stock values Reservation reduction Actual costs calculation and update for order


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Unit 7 Confirmations Unit Overview Topics: • •

Confirmation procedure Confirmations and material movements


Carry out confirmations for process orders using different procedures Set up confirmation parameters in Customizing Describe the different goods movements options during confirmation

Unit Contents Lesson: Confirmation Procedures ............................................406 Exercise 31: Function of Confirmations and Confirmation Procedures ..................................................................413 Exercise 32: Defining Confirmation Parameters in Customizing .....417 Exercise 33: Confirmation Procedures ..................................421 Lesson: Confirmations and Material Movements ...........................447 Exercise 34: Order Confirmation with Backflushing and Automatic Goods Receipt ..............................................................453

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Unit 7: Confirmations

SCM340

Lesson: Confirmation Procedures Lesson Overview This lesson informs you about the possible confirmation procedures.


Carry out confirmations for process orders using different procedures Set up confirmation parameters in Customizing

Business Example You will test the different procedures for confirming process orders. You will set up the relevant parameters in Customizing.

Confirmations

Figure 79: Confirmations

Confirmations record the tasks that have been performed for the order. Confirmations document the state of processing for process orders, operations, phases, and secondary resources.

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Lesson: Confirmation Procedures

Confirmations are recorded for the phases and secondary resources. Since costing, scheduling, and capacity requirements planning are only based on the phase data and secondary resource data, operations are not confirmed. The graphic illustrates which data you can confirm and which business transactions are carried out as a result. To confirm order data, you can use both the R/3 confirmation transactions and process messages from within the PI sheet or a process control system. Confirmations can be used to trigger backflushing and automatic goods receipts.

Confirmation Procedures

Figure 80: Confirmation Procedures

You can enter confirmations for phases and secondary resources. If you enter a confirmation for a phase or a secondary resource, you can use either of the following options: • •

To confirm durations and activities, you enter a time ticket confirmation. To confirm a specific point in time (for example, processing start or processing finish), you enter a time event confirmation. When you confirm time events, the system calculates the confirmed duration. Parameters of time-dependent standard values must be assigned the record type group 2. Time-independent standard values can be confirmed as variable activities.

You can confirm data as follows: • •

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Manually during order processing By sending messages in process management


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Simplified Confirmation Procedures

Figure 81: Simplified Confirmation Procedures

If you enter a confirmation for the order, the phases/secondary resources are confirmed in accordance with the formulas defined for the standard values. • •

Quantity-dependent standard values of phases / secondary resources are confirmed in proportion to the confirmed order quantity. If the standard values are quantity-independent, the confirmed values are identical to the planned values.

You can use the collective confirmation function to confirm data of several phases and secondary resources belonging to different orders. The standard values of the phases / secondary resources are confirmed in accordance with the formulas assigned. • •

408

Quantity-dependent standard values of phases / secondary resources are confirmed in proportion to the confirmed operation quantity. If the standard values are quantity-independent, the confirmed values are identical to the planned values.


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Customizing: Confirmation Parameters

Figure 82: Customizing: Confirmation Parameters

In Customizing, you define confirmation parameters for each order type and plant (fixed parameters). When you enter a confirmation, you can change some of these settings in the dialog (variable parameters). Using the confirmation parameters, you specify the following, for example: • • •

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Which entry screen is offered by default Which data the system proposes during data entry How strictly you want checks to be carried out


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Customizing: Single-Screen Entry

Figure 83: Customizing: Single-Screen Entry

In this step you define the confirmation profiles for the single-screen entry of time ticket confirmations and for the postprocessing of incorrect time ticket confirmations. You can define the layout of the entry screen. To do this, you specify which input and output fields are displayed in what order. These definitions are grouped into profiles. In the user parameter CORUPROF, a profile is assigned to the individual end user. In the header area, you can define which data should identify the phase to be confirmed or the secondary resources. Here, for example, you can differentiate between whether only the confirmation number can be entered for the defined profile, or whether the order, phase, and secondary resources can also be entered. In the detail areas you specify which information can be entered for the phase to be confirmed or the secondary resources, and in which order the related fields are presented. The postprocessing indicator specifies whether the profile is used for the single-screen entry or for the postprocessing of incorrect time ticket confirmations. Under a profile name, there can be one definition for each application case. You use the Standard profile indicator to specify that the profile is to be used as a standard profile. Only one profile can be defined as a standard profile for each of the single-screen entry and the postprocessing of incorrect time ticket confirmations. The standard profile is used when the user in the user parameter CORUPROF is not assigned a profile, or if the profile assigned does not exist.

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Confirmation Using a Process Message: Example

Figure 84: Confirmation Using a Process Message: Example

You can use process messages to confirm data from a process control system or a PI sheet. The graphic illustrates how you enter a time event confirmation from within a PI sheet. In our example, a process message of category PI_PHST is created when a signature is entered. This message confirms the start of phase 110. The message is sent to the corresponding message destination. The message destination for message category PI_PHST is the Confirmation for phase function module. This function module posts the confirmation. The following process message categories that you can use for confirmations have been predefined by SAP: Time event confirmations: • • • •

PI_PHACT Message on activities (phase) PI_PHST Message on phase status PI_SRACT Message on activities (secondary resource) PI_SRST Message on secondary resource status

Time ticket confirmations: • •

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PI_PHCON Time ticket confirmation for phase PI_SRCON Time ticket confirmation for secondary resource


411


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Exercise 31: Function of Confirmations and Confirmation Procedures Exercise Objectives After completing this exercise, you will be able to: • Explain the function of confirmations • Name the possible confirmation procedures

Business Example Disciplined confirmations as close to real time as possible are one of the main requirements for meaningful process control and useful process evaluations. You will get an overview of the confirmation function for process orders. In addition, you will be introduced to different confirmation procedures.

Task 1: 1.

Describe the function of confirmations. Which data can you confirm? Which business transactions are carried out as a result of confirmations? Notes: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________


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Task 2: 1.

Outline the different confirmation procedures. Notes: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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Solution 31: Function of Confirmations and Confirmation Procedures Task 1: 1.

Describe the function of confirmations. Which data can you confirm? Which business transactions are carried out as a result of confirmations? Notes: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

For information on confirmations, see the page “„Confirmations” in your participant handbook.

Task 2: 1.

Outline the different confirmation procedures. Notes: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Continued on next page

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____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

416

For information on confirmation procedures, see the pages “„Confirmation Procedures” and “„Simplified Confirmation Procedures” in your participant handbook.


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Exercise 32: Defining Confirmation Parameters in Customizing Exercise Objectives After completing this exercise, you will be able to: • Define confirmation parameters for the order type • Set up profiles for the single-screen entry of time ticket confirmations

Business Example You will make the necessary Customizing settings to make confirmations for process orders.

Task 1: 1.

Define the confirmation parameters in Customizing for plant 1100 and order type PO## as described in the following paragraphs:

2.

Do not make any entries on the Generally valid settings tab. If required, use F1 and F4 help to get information about the fields and settings that can be made.

3.

Choose the General individual entry tab. Specify that you want the system to always propose a final confirmation.

4.

Specify that you want the system to create a log of the actual costs when you confirm activities.

5.

Choose the Operation indiv. entry using initial scrn tab. Specify that you want the system to propose the quantities that according to planning have yet to be confirmed. Specify that you want the system to display confirmed quantities. Specify that you want the system to display the total quantities to be confirmed.

6.

Specify that you want the system to propose the activities that according to planning have yet to be confirmed. Specify that you want the system to display confirmed activities. Specify that you want the system to display the total activities to be confirmed. Continued on next page

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7.

Specify that you want the system to display confirmed dates.

8.

Do not make any further entries or changes. If required, use field help (F1) for information on the other confirmation parameters. Save your confirmation parameters.

Task 2: 1.

In Customizing, call the profile SCM340_001 for the single-screen entry of time ticket confirmations. Analyze the settings for the profile. Note the the Standard profile indicator is set in the profile.

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Solution 32: Defining Confirmation Parameters in Customizing Task 1: 1.

Define the confirmation parameters in Customizing for plant 1100 and order type PO## as described in the following paragraphs: a)

Customizing: Production Planning for Process Industries → Process Order → Operations → Confirmation → Define Confirmation Parameters Choose New Entries. Plant: 1100 Order type: PO##

2.

Do not make any entries on the Generally valid settings tab. If required, use F1 and F4 help to get information about the fields and settings that can be made. a)

Choose the Generally valid settings tab. Do not make any changes on this tab.

3.

Choose the General individual entry tab. Specify that you want the system to always propose a final confirmation. a)

Choose the General individual entry tab. Confirmation function: Confirm. type: Final confirmation

4.

Specify that you want the system to create a log of the actual costs when you confirm activities. a)

Error handling/logs: X Actual costs

5.

Choose the Operation indiv. entry using initial scrn tab. Specify that you want the system to propose the quantities that according to planning have yet to be confirmed. Specify that you want the system to display confirmed quantities.


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Specify that you want the system to display the total quantities to be confirmed. a)

Choose the Operation indiv. entry using initial scrn tab. Quantities: X Propose X Display confirmed quantities X Display defaults

6.

Specify that you want the system to propose the activities that according to planning have yet to be confirmed. Specify that you want the system to display confirmed activities. Specify that you want the system to display the total activities to be confirmed. a)

Activities: X Propose X Display confirmed activities X Display defaults

7.

Specify that you want the system to display confirmed dates. a)

Dates: X Display confirmed dates

8.

Do not make any further entries or changes. If required, use field help (F1) for information on the other confirmation parameters. Save your confirmation parameters. a)

See description

Task 2: 1.

In Customizing, call the profile SCM340_001 for the single-screen entry of time ticket confirmations. Analyze the settings for the profile. Note the the Standard profile indicator is set in the profile. a)

420

Customizing: Production Planning for Process Industries → Process Order → Operations → Confirmation → Single-Screen Entry → Define Single Screen Entry


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Exercise 33: Confirmation Procedures Exercise Objectives After completing this exercise, you will be able to: • Use process messages to perform time ticket confirmations, time event confirmations, and confirmations

Business Example You will test different confirmation procedures.

Task 1: Manual time ticket confirmations (tasks 1 to 5) 1.

Display the stock/requirements list for material T-FF9## in plant 1100. If you have done the exercises in the previous unit as described, the following data will be displayed: T-FF9## Date

MRP element

MRP element Recpt/Reqd data qty

Available quantity

Today

STOCK

Today

PR-ORD

Order no. / PO##

1000

1000

Today + 1 week

PR-ORD

Order no. / PO##

1000

2000

0

Hint: In the following exercises, only the process order that is chronologically first will be taken into account.

Task 2: 1.

Display the process order that is chronologically first from the stock/requirements list. Write down the order number: ______________________________

2.

Go to the operation overview. Continued on next page

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Write down the operation and phase statuses: Operation

Phase

Status

0100 0110 0200 0210 0220 3.

Display the general data for each phase and write down the assigned confirmation number for each of them: Phase

Confirmation number

0110 0210 0220 4.

Write down the quantities and activities for each phase: Phase

Confirmed yield

Operation quantity

Confirmed (activity)

To confirm (activity)

0110 0210 0220 5.

Display the costs incurred by your order. Note that there are no actual costs yet with regard to the confirmations.

Task 3: 1.

Carry out a time ticket confirmation for phase 110. Enter a confirmation with reference to the corresponding confirmation number.

2.

Compare the default values and information displayed for the confirmation with your Customizing settings. Save the confirmation. Continued on next page

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3.

Display the operation overview of your order. Write down the following: Operation

Phase

Status

0100 0110 0200 0210 0220 4.

Write down the quantities and activities for phase 110. Phase

Confirmed yield

Operation quantity



0110 5.

Display the costs incurred by your order. Note the actual costs with regard to your confirmation.

6.

Which new order status has been set? ______________________________________________________

Task 4: 1.

Carry out a time ticket confirmation for phase 210. Enter the confirmation with reference to the process order number and to phase 210.

2.

Compare the default values and information displayed for the confirmation with your Customizing settings. Save the confirmation.

Task 5: 1.

Carry out a time ticket confirmation for phase 220. Enter the confirmation with reference to the process order number and to phase 220. Continued on next page

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2.

SCM340

Then display the operation overview of your order. Write down the following: Operation

Phase

Status

0100 0110 0200 0210 0220 3.

Write down the quantities and activities for phases 210 and 220. Phase

Confirmed yield

Operation quantity



0210 0220 4.

Display the costs incurred by your order. Note the actual costs with regard to your confirmations.

5.

Which new order status has been set? ______________________________________________________

Task 6: Time ticket confirmations using process messages (tasks 6 to 11) 1.

Note: The following exercise aims at illustrating time ticket confirmation using process messages by having you maintain a PI sheet with reference to the above master recipe T-RC9#. In this scenario, we only want you to make confirmations in the PI sheet. The process instructions have been created for control recipe destination FA. Therefore, make the following changes in your master recipe:

2.

Replace the control recipe destination assigned to all phases with the new destination FA. Save your recipe. Continued on next page

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Task 7: 1.

Create another process order of order type PO## for material T-FF9## in plant 1100. Enter 1,000 L as the quantity to be produced. Enter Today +2 weeks as the basic start date.

2.


3.


Task 8: 1.


Task 9: 1.

Find and maintain the PI sheet. In this scenario, the PI sheet’s only purpose is to record and report activities (= duration) performed. The planned values from the order are set as default values. You can overwrite these values. By executing your signature (with ECC user and ECC password) at the end of the PI sheet, you transfer the process messages containing the activities recorded to the message monitor.

Task 10: 1.

Go to the message monitor and analyze the messages of message category PI_PHCON that were created while you maintained the PI sheet. Send the messages.

Task 11: 1.

Display the process order. Continued on next page

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2.

Display the operation overview of your order. Note the operation and phase statuses.

3.

Display the quantities and activities for the phases.

4.

Display the costs incurred by your order.

5.

Which order status has been set with regard to the confirmations? ______________________________________________________

Task 12: Manual time event confirmations (tasks 12 and 13) 1.


2.

Make sure that the order was automatically released after order creation.

3.


Task 13: 1.

Carry out a time event confirmation for phase 110.

2.

Confirm the start of phase processing. Enter the confirmation with reference to the order number.

3.

Choose the present date and time as the processing start. Save your confirmation.

4.

In another time event confirmation, you report the end of the processing of phase 110 in the same way. Choose the present date and time as the processing end. Save your confirmation.

5.

Display the operation overview of your order. Write down the following:


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Operation

Phase

Status

0100 0110 0200 0210 0220 6.

Display the dates confirmed for phase 110.

7.


Confirmed yield

Operation quantity



0110 How did the system calculate the confirmed duration? ______________________________________________________ 8.

Display the cost analysis for your order.

Task 14: Time event confirmations using process messages (tasks 14 to 19) 1.

Note: The following exercise aims at illustrating time event confirmation using process messages by having you maintain a PI sheet with reference to the above master recipe T-RC9#. In this scenario, we only want you to make time event confirmations in the PI sheet. The process instructions have been created for control recipe destination FT. Therefore, make the following changes in your master recipe:

2.

Replace the control recipe destination assigned to all phases with the new destination FT. Save your recipe.


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Task 15: 1.


2.


3.


Task 16: 1.


Task 17: 1.

Find and maintain the PI sheet. You report the start and finish of each phase by executing your signature in the PI sheet. Every signature triggers a time event confirmation.

Task 18: 1.

Go to the message monitor and analyze the messages of message category PI_PHST that were created while you maintained the PI sheet. Send the messages.

Task 19: 1.


2.

Display the operation overview of your order. Write down the following: Continued on next page

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Operation

Phase

Status

0100 0110 0200 0210 0220

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3.

Display the dates confirmed for the phases.

4.

Display the quantities and activities for the phases.

5.

Display the cost analysis for your order.


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Solution 33: Confirmation Procedures Task 1: Manual time ticket confirmations (tasks 1 to 5) 1.

Display the stock/requirements list for material T-FF9## in plant 1100. If you have done the exercises in the previous unit as described, the following data will be displayed: T-FF9## Date

MRP element

MRP element Recpt/Reqd data qty

Available quantity

Today

STOCK

Today

PR-ORD

Order no. / PO##

1000

1000

Today + 1 week

PR-ORD

Order no. / PO##

1000

2000

0

Hint: In the following exercises, only the process order that is chronologically first will be taken into account. a)

Logistics → Production - Process → Process Order → Environment → Stock/Requirements List Material: T-FF9## Plant: 1100 Enter

Task 2: 1.

Display the process order that is chronologically first from the stock/requirements list. Write down the order number: ______________________________ a)

Position the cursor on the process order that is chronologically first and choose the Display element icon. The order header appears. Write down the order number. Continued on next page

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2.

Go to the operation overview. Write down the operation and phase statuses: Operation

Phase

Status

0100 0110 0200 0210 0220 a)

Choose Operations. Operation

Phase

Status

0100

CRCR REL 0110

CRCR REL

0200

3.

CRCR REL 0210

CRCR REL

0220

CRCR REL

Display the general data for each phase and write down the assigned confirmation number for each of them: Phase

Confirmation number

0110 0210 0220 a) 4.

Double-click the relevant phase number and choose the General data tab.

Write down the quantities and activities for each phase:


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Phase

Confirmed yield

Operation quantity



0110 0210 0220 a)

5.

Choose the Qty/activities tab for the phase. Phase

Confirmed yield

Operation quantity



0110

0

1000 L

0

15 MIN

0210

0

1000 L

0

20 MIN

0220

0

1000 L

0

10 MIN

Display the costs incurred by your order. Note that there are no actual costs yet with regard to the confirmations. a)

Goto → Costs → Analysis No actual costs have been recorded yet with regard to the confirmations.

Task 3: 1.

Carry out a time ticket confirmation for phase 110. Enter a confirmation with reference to the corresponding confirmation number. a)

(…) → Process Order → Confirmation → Enter for Phase → Time Ticket Confirmation: Confirmation number for phase 110 (see exercise 2-3)

2.

Compare the default values and information displayed for the confirmation with your Customizing settings. Save the confirmation. a)

3.

See exercise

Display the operation overview of your order. Write down the following:


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Operation

Phase

Status

0100 0110 0200 0210 0220 a) Operation

Phase

Status

0100

CRCR CNF REL 0110

CRCR CNF REL

0200

4.

CRCR REL 0210

CRCR REL

0220

CRCR REL


Confirmed yield

Operation quantity



0110 a)

5.

Phase

Confirmed yield

Operation quantity



0110

1000 L

1000 L

15 MIN

15 MIN

Display the costs incurred by your order. Note the actual costs with regard to your confirmation. a)

6.

Due to the confirmation made for phase 110, the relevant actual costs were updated.

Which new order status has been set? ______________________________________________________ a)

Go to the order header. PCNF Partially confirmed Continued on next page

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Task 4: 1.

Carry out a time ticket confirmation for phase 210. Enter the confirmation with reference to the process order number and to phase 210. a)

(…) → Process Order → Confirmation → Enter for Phase → Time Ticket Order: Order number Phase: 210

2.

Compare the default values and information displayed for the confirmation with your Customizing settings. Save the confirmation. a)

See exercise

Task 5: 1.

Carry out a time ticket confirmation for phase 220. Enter the confirmation with reference to the process order number and to phase 220. a)

(…) → Process Order → Confirmation → Enter for Phase → Time Ticket Order: Order number Phase: 220

2.

Then display the operation overview of your order. Write down the following: Operation

Phase

Status

0100 0110


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Operation

Phase

Status

0200 0210 0220 a) Operation

Phase

Status

0100

CRCR CNF REL 0110

CRCR CNF REL

0200

3.

CRCR CNF REL 0210

CRCR CNF REL

0220

CRCR CNF REL

Write down the quantities and activities for phases 210 and 220. Phase

Confirmed yield

Operation quantity



0210 0220 a)

4.

Phase

Confirmed yield

Operation quantity



0210

1000 L

1000 L

20 MIN

20 MIN

0220

1000 L

1000 L

10 MIN

10 MIN

Display the costs incurred by your order. Note the actual costs with regard to your confirmations. a)

5.

Due to the confirmations, the relevant actual costs were updated.

Which new order status has been set? ______________________________________________________ a)

Go to the order header. CNF Finally confirmed Continued on next page

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Task 6: Time ticket confirmations using process messages (tasks 6 to 11) 1.

Note: The following exercise aims at illustrating time ticket confirmation using process messages by having you maintain a PI sheet with reference to the above master recipe T-RC9#. In this scenario, we only want you to make confirmations in the PI sheet. The process instructions have been created for control recipe destination FA. Therefore, make the following changes in your master recipe: a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Change Recipe group: T-RC9##

2.

Replace the control recipe destination assigned to all phases with the new destination FA. Save your recipe. a)

See description

Task 7: 1.

Create another process order of order type PO## for material T-FF9## in plant 1100. Enter 1,000 L as the quantity to be produced. Enter Today +2 weeks as the basic start date. a)

Logistics → Production - Process → Process Order → Process Order → Create → With Material Material number: T-FF9## Production plant: 1100 Process order type: PO## Enter Total quantity: 1,000 L Start: Today + 2 weeks Enter Continued on next page

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2.


3.


Save the order and write down the order number: ______________________________________________________ a)

See description

Task 8: 1.



Task 9: 1.

Find and maintain the PI sheet. In this scenario, the PI sheet’s only purpose is to record and report activities (= duration) performed. The planned values from the order are set as default values. You can overwrite these values. By executing your signature (with ECC user and ECC password) at the end of the PI sheet, you transfer the process messages containing the activities recorded to the message monitor. a)


Task 10: 1.

Go to the message monitor and analyze the messages of message category PI_PHCON that were created while you maintained the PI sheet.


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Task 11: 1.


2.

Display the operation overview of your order. Note the operation and phase statuses. a)

3.

Usual procedure

Display the costs incurred by your order. a)

5.

Choose Operations.

Display the quantities and activities for the phases. a)

4.


Usual procedure

Which order status has been set with regard to the confirmations? ______________________________________________________ a)

Go to the order header. CNF Finally confirmed

Task 12: Manual time event confirmations (tasks 12 and 13) 1.

Create another process order of order type PO## for material T-FF9## in plant 1100. Enter 1,000 L as the quantity to be produced.


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Enter Today +3 weeks as the basic start date. a)

Logistics → Production - Process → Process Order → Process Order → Create → With Material Material number: T-FF9## Production plant: 1100 Process order type: PO## Enter Total quantity: 1,000 L Start: Today +3 weeks Enter

2.

Make sure that the order was automatically released after order creation. a)

3.

The order status REL must have been set after order creation.


See description

Task 13: 1.

Carry out a time event confirmation for phase 110. a)

2.

(…) → Process Order → Confirmation → Enter for Phase → Time Event

Confirm the start of phase processing. Enter the confirmation with reference to the order number. a)

X Start processing Process order: Order number Choose Enter. The system proposes the phases still to be confirmed. Select phase 110 and choose the Details icon.

3.

Choose the present date and time as the processing start.


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Save your confirmation. a)

The Create Confirmation of Time Event: Actual Data screen appears. Start processing: Current date Current time Use possible entries help (F4) to enter the date and time. Save your confirmation.

4.

In another time event confirmation, you report the end of the processing of phase 110 in the same way. Choose the present date and time as the processing end. Save your confirmation. a)

(…) → Process Order → Confirmation → Enter for Phase → Time Event X Finish processing Process order: Order number Enter Select phase 110 Details icon Finish processing: Current date Current time Save.

5.


Phase

Status

0100 0110


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Operation

Phase

Status

0200 0210 0220 a)

(…) Process Order → Display Choose Operations. Operation

Phase

Status

0100

CRCR CNF REL 0110

CRCR CNF PRFN REL

0200

6.

0210

CRCR REL

0220

CRCR REL

Display the dates confirmed for phase 110. a)

7.

CRCR REL

Double-click phase number 110 and choose the Dates tab.


Confirmed yield

Operation quantity



0110 How did the system calculate the confirmed duration? ______________________________________________________ a)

Choose the Qty/activities tab. Phase

Confirmed yield

Operation quantity



0110

1000 L

1000 L

Calculated duration

15 MIN

The system used the difference between the processing finish and the processing start of phase 110 to calculate the duration.


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Display the cost analysis for your order. a)

As a result of the confirmation for phase 110, actual costs were updated.

Task 14: Time event confirmations using process messages (tasks 14 to 19) 1.

Note: The following exercise aims at illustrating time event confirmation using process messages by having you maintain a PI sheet with reference to the above master recipe T-RC9#. In this scenario, we only want you to make time event confirmations in the PI sheet. The process instructions have been created for control recipe destination FT. Therefore, make the following changes in your master recipe: a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Change Recipe group: T-RC9##

2.

Replace the control recipe destination assigned to all phases with the new destination FT. Save your recipe. a)

See description

Task 15: 1.

Create another process order of order type PO## for material T-FF9## in plant 1100. Enter 1,000 L as the quantity to be produced.


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Enter Today +4 weeks as the basic start date. a)

Logistics → Production - Process → Process Order → Process Order → Create → With Material Material number: T-FF9## Production plant: 1100 Process order type: PO## Enter Total quantity: 1,000 L Start: Today +4 weeks Enter

2.


3.



See description

Task 16: 1.



Task 17: 1.

Find and maintain the PI sheet. You report the start and finish of each phase by executing your signature in the PI sheet. Every signature triggers a time event confirmation. a)



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Task 18: 1.

Go to the message monitor and analyze the messages of message category PI_PHST that were created while you maintained the PI sheet. Send the messages. a)


Task 19: 1.


2.



Phase

Status

0100 0110 0200 0210 0220 a) 3.

Display the dates confirmed for the phases. a)

4.

Choose Operations. Double-click the relevant phase number and choose the Dates tab.

Display the quantities and activities for the phases. a)

Choose the Qty/activities tab. Continued on next page

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5.

Display the cost analysis for your order. a)

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As a result of the confirmation for the phases, actual costs were updated.


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Lesson Summary You should now be able to: • Carry out confirmations for process orders using different procedures • Set up confirmation parameters in Customizing

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Lesson: Confirmations and Material Movements

Lesson: Confirmations and Material Movements Lesson Overview This lesson familiarizes you with the functions of backflushing and automatic goods receipt.


Describe the different goods movements options during confirmation

Business Example You will get an overview of the options available for performing material movements during confirmations. You will test the following functions in a sample scenario: •

Backflushing and

•

Automatic goods receipt

Goods Movements During Confirmation

Figure 85: Goods Movements During Confirmation

When you enter a confirmation, you can post both planned and unplanned material movements.

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You can enter planned goods movements during confirmation as follows: •

Backflushing When you confirm an order or phase that has been assigned components for which the Backflushing indicator has been set, the system automatically posts a goods issue for these components.

•

Automatic goods receipt If the control key assigned to the phase that you confirm specifies that an automatic goods receipt must be made, the system automatically posts the delivered material to the stock.

Unplanned goods movements: You can navigate to a material overview from the confirmation. You can enter any number of unplanned material movements or change planned material movements on this material overview. Note that in PP-PI you can use process messages from process control to post material movements. If you use this function, do not trigger material postings from the confirmation.

Backflushing (I)

Figure 86: Backflushing (I)

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A goods issue has to be posted for every material that is withdrawn during order processing. Goods issue posting can be carried out: • •

Directly when the material is withdrawn Automatically when you confirm the phase to which the material component has been assigned (backflushing)

You can use backflushing, for example, if you do not want to physically issue a material from the warehouse with reference to an order. The system assumes that the material is staged at the resource. Note that you can only confirm phases in the process order. For this reason, you cannot backflush a material if the material component is assigned to an operation in the process order. You can navigate to a material overview from the confirmation. In Customizing, you can define whether you want this overview to list all components assigned to the phase or only those that must be backflushed. You can enter any number of unplanned material movements or change planned material movements on this material overview. Note that in PP-PI you can use process messages (for example, PI_CONS) from process control to post material movements. If you use this function, we recommend that you do not trigger goods issues from the confirmation, or set the filter for the control recipe destination accordingly for generated process instructions.

Backflushing (II)

Figure 87: Backflushing (II)

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To determine whether a material is to be backflushed, you can make settings in: • • • •

The material master record (MRP view) The resource (Basic Data screen) The master recipe (General Data screen for component assignment) The process order (General Data screen for the material component)

When you create a process order, the settings made in the master recipe are copied to the order. However, you can still change them. If you set the Backflush indicator in the process order, the material is always backflushed regardless of what you entered in the material master record. If you do not set the indicator in the process order, it depends on the settings in the material master record whether the material is backflushed or not. In the material master record, you can determine whether the material is always to be backflushed or whether it depends on the settings in the resource. The graphic shows where you must set which indicators to control backflushing.

Automatic Goods Receipt

Figure 88: Automatic Goods Receipt

In the control key of a phase, you can specify that the system should automatically post the finished material to stock when the phase is confirmed.

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An automatic goods receipt can only be posted for one phase per order. You should therefore make sure that only one phase in the order (normally the last phase) has a control key that specifies automatic goods receipt. If you want to use automatic goods receipt in process manufacturing, make sure that the operation quantity (confirmed quantity) is identical with the quantity produced. Note: As a basis for activity calculation, the operation quantity processed is confirmed. In process manufacturing, this need not necessarily be identical to the yield produced. If you want to use process messages (for example, PI_PROD) to post goods receipts, do not trigger an automatic goods receipt from confirmation.

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Exercise 34: Order Confirmation with Backflushing and Automatic Goods Receipt Exercise Objectives After completing this exercise, you will be able to: • Enter the settings for backflushing • Enter the settings for an automatic goods receipt • Perform the confirmation for a complete order with backflushing and automatic goods receipt

Business Example To simplify order processing, you decide not to use process management for the process orders that produce your fertilizer T-FF9## and to use the simplified confirmation process for order confirmation instead. You also want backflushing to be triggered when assigned material components are confirmed and an automatic goods receipt to be posted for the product T-FF9##.

Task 1: Goods movements during confirmation (exercises 1 and 2) 1.

How can you enter planned goods movements at confirmation? Notes: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

Task 2: 1.

What must you also be aware of with regard to goods movements at confirmation if you want to use process management? Notes: Continued on next page

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____________________________________________________________ ____________________________________________________________ ____________________________________________________________

Task 3: Settings for backflushing 1.

Where can you specify that a material component is to be backflushed?

Task 4: 1.

For the production process for fertilizer T-FF9##, the assigned material components T-RF7##, T-RF8##, and T-RF9## are to be backflushed at confirmation. Make the required settings in the material list of the master recipe T-RC9##.

Task 5: Settings for the default issuing storage location (exercises 5 and 6) 1.

Display the MRP 2 view in the material master record for material components T-RF7## and T-RF9##. Write down the following: Production storage location: ________ Use the F1 help to display information on the meanings of these fields with regard to backflushing. Note: The components T-RF7## and T-RF9## are not managed in batches.

Task 6: 1.

Display the MRP2 view in the material master record for the material component T-RF8##, which is managed in batches. Write down the following: Batch entry: ____ Production storage location: ________ How is the default issuing storage location assigned to this material component in the process order? Continued on next page

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____________________________________________________________ ____________________________________________________________ ____________________________________________________________

Task 7: Settings for an automatic goods receipt For the fertilizer production process, the goods receipt for the product T-FF9## is to be automatically posted at order confirmation. 1.

In master recipe T-RC9##, choose the appropriate control key PI05 for the last phase 220. Display the detail information for this control key. Check whether the setting for an automatic goods receipt at confirmation has been made.

2.

Display the Work scheduling view for product T-FF9## in the material master. Write down the following: Prod. storage location: ________ Use the field help (F1) to display information on the meaning of this field.

Task 8: Order confirmation with backflushing and automatic goods receipt (exercises 8 to 10) 1.

Create a process order for material T-FF9## in plant 1100. Use order type PO##. Enter 2000 L as the quantity to be produced. Enter Today +5 weeks as the basic start date.

2.

Make sure that the following activities also take place automatically at order creation: - Order release - Batch number assignment for the product T-FF9## - Batch determination for material component T-RF8##

3.

Check whether the storage location defaults for the automatic goods receipt or backflushing are correctly copied or determined for the product and the material components. Continued on next page

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Save your order and write down the order number. ______________________

Task 9: 1.

Enter an order confirmation for your process order.

2.

Confirm a yield of 1000 L and choose the option Final confirmation.

3.

Display the list of the automatic goods movements. Note the quantity data in the list. If required, compare them to the planned values in the order. Note the Completed indicator. It is set automatically when the final confirmation is made. Note that you can still change the data in the list. Note that unplanned goods movements are possible.

4.

Save the confirmation and write down the system messages. ______________________________________________________ ______________________________________________________

Task 10: 1.

Display your process order.

2.

Which order status was set with regard to the confirmation and the goods movements? ______________________________________________________ ______________________________________________________ ______________________________________________________

3.

Display the goods movement list in the order.

4.

Write down the General Data for the order header: Total quantity: ____________ Delivered: ____________

5.

Write down the issue quantities for your material components for the order compared to the planned requirements quantities. Continued on next page

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Material

Reqmts quantity

Committed qty

T-RF7## T-RF9## Batch for T-RF8## Interpret the result. ______________________________________________________ ______________________________________________________ ______________________________________________________ 6.

Write down the planned confirmed activities and the actual confirmed activities for the phases. Phase

Confirmed

To be confirmed

110 210 220 Interpret the result. Why were the confirmed activities not adjusted proportionally to the confirmed yield in our scenario? ______________________________________________________ ______________________________________________________ ______________________________________________________

Task 11: 1.

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Solution 34: Order Confirmation with Backflushing and Automatic Goods Receipt Task 1: Goods movements during confirmation (exercises 1 and 2) 1.

How can you enter planned goods movements at confirmation? Notes: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

For information on goods movements during confirmation, see the page “„Goods Movements During Confirmation” in your participant handbook.

Task 2: 1.

What must you also be aware of with regard to goods movements at confirmation if you want to use process management? Notes: ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

For information on goods movements during confirmation, see the page “„Goods Movements During Confirmation” in your participant handbook.


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Task 3: Settings for backflushing 1.

Where can you specify that a material component is to be backflushed? a)

For information on backflushing, see the page “„Backflushing (II)” in your participant handbook.

Task 4: 1.

For the production process for fertilizer T-FF9##, the assigned material components T-RF7##, T-RF8##, and T-RF9## are to be backflushed at confirmation. Make the required settings in the material list of the master recipe T-RC9##. a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Change Recipe group: T-RC9## Materials Select your material components and then choose the Assignment details icon in the lower toolbar. Set the following indicator for each material component on the General data tab X Backflushing Save your master recipe.

Task 5: Settings for the default issuing storage location (exercises 5 and 6) 1.

Display the MRP 2 view in the material master record for material components T-RF7## and T-RF9##. Write down the following: Production storage location: ________ Use the F1 help to display information on the meanings of these fields with regard to backflushing.


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Note: The components T-RF7## and T-RF9## are not managed in batches. a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-RF7## or T-RF9## Enter X MRP2 Enter Plant: 1100 Enter MRP2 view: Production storage location: 0002

Task 6: 1.

Display the MRP2 view in the material master record for the material component T-RF8##, which is managed in batches. Write down the following: Batch entry: ____ Production storage location: ________ How is the default issuing storage location assigned to this material component in the process order? ____________________________________________________________ ____________________________________________________________


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____________________________________________________________ a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-RF8## Enter X MRP2 Enter Plant: 1100 Enter MRP2 view: Batch entry: 3 Production storage location: ____ When an order is released, batch determination is automatically carried out for this material. The issuing storage location is determined via batch determination.

Task 7: Settings for an automatic goods receipt For the fertilizer production process, the goods receipt for the product T-FF9## is to be automatically posted at order confirmation. 1.

In master recipe T-RC9##, choose the appropriate control key PI05 for the last phase 220. Display the detail information for this control key.


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Check whether the setting for an automatic goods receipt at confirmation has been made. a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Change Recipe group: T-RC9## Operations Replace the existing control key PI01 in phase 220 with the new control key PI05. Position the cursor on the new control key and choose the F4 help. The Control key screen appears. Position the cursor on control key PI05 and choose Detail info. X Autom. goods receipt Save your master recipe.

2.

Display the Work scheduling view for product T-FF9## in the material master. Write down the following: Prod. storage location: ________ Use the field help (F1) to display information on the meaning of this field. a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-FF9## Enter X Work scheduling Enter Plant: 1100 Enter Work scheduling view: Prod. storage location: 0001

Task 8: Order confirmation with backflushing and automatic goods receipt (exercises 8 to 10) 1.

Create a process order for material T-FF9## in plant 1100. Continued on next page

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Use order type PO##. Enter 2000 L as the quantity to be produced. Enter Today +5 weeks as the basic start date. a)


T-FF9##

Production plant:

1100

Process order type:

PO##

Enter Total quantity: 2000 L Start: Today + 5 weeks Enter 2.

Make sure that the following activities also take place automatically at order creation: - Order release - Batch number assignment for the product T-FF9## - Batch determination for material component T-RF8## a)

3.

No further details required

Check whether the storage location defaults for the automatic goods receipt or backflushing are correctly copied or determined for the product and the material components. Save your order and write down the order number.


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______________________ a)

On the order header, choose the Goods receipt tab. Storage location: 0001 Batch: Batch number The storage location for the automatic goods receipt was copied from the material master record of product T-FF9##. Choose Materials. Material

Storage location

T-RF7##

0002

T-RF9##

0002

T-RF8##

0002

For the material components T-RF7## and T-RF9##, the storage location was copied from the material master record. For the material components T-RF8##, the storage location was determined at batch determination. Save your order.

Task 9: 1.

Enter an order confirmation for your process order. a)

Logistics → Production - Process → Process Order → Confirmation → Enter for Order Process order: Order number Enter

2.

Confirm a yield of 1000 L and choose the option Final confirmation. a)

X Final conf. Confirmed yield: 1000 L Enter The following message appears: Total confirmation quantity not equal to planned confirmation quantity Choose Enter to confirm. Continued on next page

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3.

Display the list of the automatic goods movements. Note the quantity data in the list. If required, compare them to the planned values in the order. Note the Completed indicator. It is set automatically when the final confirmation is made. Note that you can still change the data in the list. Note that unplanned goods movements are possible. a)

4.

Choose Goods movements.

Save the confirmation and write down the system messages. ______________________________________________________ ______________________________________________________ a)

Save your confirmation. After you save, you get the message: Confirmation saved. Goods movements: 4, errors: 0

Task 10: 1.

Display your process order. a)

2.


Which order status was set with regard to the confirmation and the goods movements? ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

Choose the Status icon for the status line in the order header. CNF Finally confirmed DLV Delivered GMPS Goods movement posted

3.

Display the goods movement list in the order. a)

4.

Goto → Lists → Documented Goods Movements

Write down the General Data for the order header: Total quantity: ____________ Continued on next page

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Delivered: ____________ a)

On the order header, choose the General data tab. Total quantity: 2000 L Delivered: 1000 L Only half of the planned quantity was produced.

5.

Write down the issue quantities for your material components for the order compared to the planned requirements quantities. Material

Reqmts quantity

Committed qty

T-RF7## T-RF9## Batch for T-RF8## Interpret the result. ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

Choose Materials. Select the material components T-RF7## and T-RF9## and the batch for material component T-RF8##. Choose Mat. detail in the lower toolbar. Material

Reqmts quantity

Committed qty

T-RF7##

1800 L

900 L

T-RF9##

60 KG

30 KG

Batch for T-RF8##

140 L

70 L

Only half of the planned requirements quantities were posted for backflushing because only half (1000 L) of the planned production quantity (2000 L) was confirmed. Due to the final confirmation (status CNF) the Final issue indicator was set. 6.

Write down the planned confirmed activities and the actual confirmed activities for the phases. Continued on next page

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Phase

Confirmed

To be confirmed

110 210 220 Interpret the result. Why were the confirmed activities not adjusted proportionally to the confirmed yield in our scenario? ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

Choose Operations. Double-click the relevant phase number and choose the Qty/activities tab. Phase

Confirmed

To be confirmed

110

15 MIN

15 MIN

210

20 MIN

20 MIN

220

10 MIN

10 MIN

The planned values were copied for the activities at order confirmation. In our scenario, the standard value Duration is defined as a quantity-independent standard value. This means that the processing duration of the phases is not dependent on the production quantity. You can use quantity-dependent standard values to adjust confirmed quantities to the actual quantity of goods manufactured.

Task 11: 1.

For the following exercises, reset the settings you made for backflushing and automatic goods receipt (see exercises 4 and 7-1). a)

Changes in recipe T-RC9##: Reset the Backflushing indicator in the general data for the material components. Replace control key PI05 in phase 220 with control key PI01. Save your recipe.

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Lesson Summary You should now be able to: • Describe the different goods movements options during confirmation

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Unit Summary

Unit Summary You should now be able to: • Carry out confirmations for process orders using different procedures • Set up confirmation parameters in Customizing • Describe the different goods movements options during confirmation

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Unit Summary

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Test Your Knowledge

Test Your Knowledge

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1.

Name the confirmation procedures available for process orders.

2.

What planned goods movements can be triggered by a confirmation?


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Answers 1.

Name the confirmation procedures available for process orders. Answer: • • • •

2.

Time event confirmations for phases and secondary resources Time ticket confirmations for phases and secondary resources Confirmation for the whole process order Collective confirmation for phases and secondary resources

What planned goods movements can be triggered by a confirmation? Answer: • •

472

Backflushing (automatic goods issue for material component) Automatic goods receipt (for the material produced)


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Unit 8 Goods Receipt, Order Settlement, and Order Archiving Unit Overview Topics: • • • •

Goods receipt Order settlement Order reorganization: procedure Archiving and deleting: prerequisites


Perform goods receipt postings for process orders manually using the corresponding ECC transactions Perform goods receipt postings for process orders using process messages from within the PI sheet Settle a process order and describe the general principle of order settlement Describe the process of process order reorganization

Unit Contents Lesson: Goods Receipt ........................................................474 Exercise 35: Goods Receipt ..............................................481 Lesson: Order Settlement .....................................................506 Exercise 36: Order Settlement............................................ 511 Lesson: Archiving and Deleting ...............................................523

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Unit 8: Goods Receipt, Order Settlement, and Order Archiving

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Lesson: Goods Receipt Lesson Overview This lesson informs you about goods receipt postings with reference to process orders.


Perform goods receipt postings for process orders manually using the corresponding ECC transactions Perform goods receipt postings for process orders using process messages from within the PI sheet

Business Example You will test goods receipt posting for process orders. Since not all areas in your company use the functions of process management, you must become familiar with both inventory postings using process messages and manual postings using the corresponding ECC transactions.

Order Execution and Goods Receipt

Figure 89: Order Execution and Goods Receipt

The graphic shows the main steps carried out during process order execution. The goods receipt is the last processing step.

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Lesson: Goods Receipt

Goods Receipt

Figure 90: Goods Receipt

The material components required for production are withdrawn from the warehouse as goods issues. The delivery of the material produced to the warehouse is recorded in the form of goods receipts. Both goods movements trigger the following activities in the system: • • • •

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The system creates a material document that describes the goods movement from the materials management point of view. The system creates an accounting document describing the material movement from the accounting view. The system updates the material's stock quantities. The system updates the stock values in the material master as well as the material stock and consumption accounts.


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Goods Receipt

Figure 91: Goods Receipt

You can post material receipts manually by using the corresponding ECC transactions or by sending process messages from the PI sheet or a process control system. The graphic shows the business transactions triggered by goods receipt postings. You can also post a goods receipt automatically during confirmation. If you use process management, however, do not use this function since goods receipts are posted using process messages. The Delivery completed indicator specifies whether an order is regarded as closed from the point of view of goods receipt. This means that no further goods receipts are expected for the order. The open quantity is zero. You can still post goods receipts for remaining quantities. However, they do not change the open purchase order quantity. If you have already entered a delivery for which the Delivery completed indicator has been set and still expect another delivery, you must reset the indicator.

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Goods Receipt Using a Process Message: Example

Figure 92: Goods Receipt Using a Process Message: Example

You can use process messages to trigger goods receipt postings from a process control system or the PI sheet. The graphic shows a goods receipt posting from a PI sheet. In our example, a process message of category PI_PROD to post a goods receipt is created when the fertilizer quantity produced is entered. The message is sent to the corresponding message destination. The message destination of message category PI_PROD is the Goods receipt posting function module.

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Underdelivery and Overdelivery

Figure 93: Underdelivery and Overdelivery

Underdeliveries are permitted in the standard system. You can even define an underdelivery tolerance in percentage. A goods receipt quantity that is less than the order quantity minus the underdelivery tolerance is regarded as a partial delivery and is accepted by the system. If you manually post the goods receipt, the system issues a message to inform the user about the underdelivery. In this message, it also takes the underdelivery tolerance into account. Overdeliveries are not allowed in the standard system. If you want to allow overdeliveries, you can define an overdelivery tolerance in percentage. In addition, you can deactivate the overdelivery tolerance check and thus enable unrestricted overdeliveries.

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Goods Receipt Posting to Inspection Stock

Figure 94: Goods Receipt Posting to Inspection Stock

You can post goods receipts from production to the inspection stock for one of the following reasons: •

•

•

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The material is always subject to quality inspection before it can be used. In this case, you set the indicator for the quality inspection in the material master. When you create an order, this indicator is copied from the material master to the order. You want to inspect the product manufactured in a particular process order. The production controller sets the indicator for quality inspection in the goods receipt data of the order. At the time of the goods receipt, you decide that the material quality must be checked. You set the indicator for the quality check in the goods receipt item.


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Exercise 35: Goods Receipt Exercise Objectives After completing this exercise, you will be able to: • Make manual goods receipt postings and goods receipt postings using process messages

Business Example After a material was produced by means of a process order, the quantity produced must be posted to the warehouse stock to credit the production area and to ensure the availability of the materials for follow-up activities. You will test goods receipt posting for process orders.

Task 1: 1.

Which options do you have to post goods receipts for process orders? Which business transactions are triggered by a goods receipt posting? Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: Manual goods receipt postings (tasks 2 to 7) 1.

Display the stock overview for your product T-FF9##. What stock quantities are available? ___________________________________________________________


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Task 3: 1.

Display the stock/requirements list for material T-FF9## in plant 1100. If you have done the exercises in the previous units as described, the following data should be displayed: T-FF9## Date

MRP element

MRP element data

Recpt/Reqd qty

Available quantity

Today

STOCK

Tomorrow

PR-ORD

Order no. / PO##

1000

2000

Tomorrow + 1 week

PR-ORD

Order no. / PO##

1000

3000

Tomorrow + 2 weeks

PR-ORD

Order no. / PO##

1000

4000

Tomorrow + 3 weeks

PR-ORD

Order no. / PO##

1000

5000

Tomorrow + 4 weeks

PR-ORD

Order no. / PO##

1000

6000

1000

Hint: In the following exercises, only the process order that is chronologically first will be taken into account. This is the order for which you have made goods issue postings and confirmations in the previous units. The available quantity of 1000 L comes from the automatic goods receipt of the previous unit. The process order is not displayed in the stock/requirements list anymore due to the final delivery.

Task 4: 1.

Display the process order that is chronologically first from the stock/requirements list.

2.

Go to the Goods Receipt header data screen. Which settings have been made with regard to the delivery tolerances of a goods receipt for the order?


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Underdelivery Overdelivery Unlimited overdelivery 3.

Describe what these settings control in a tolerance check. ______________________________________________________ ______________________________________________________ ______________________________________________________

4.

Where do you make the settings for the tolerance check of an order? ______________________________________________________

5.

Display the Work Scheduling view for your product T-FF9## in the material master record for plant 1100. Compare the tolerance data defined on this view with the data in your process order.

Task 5: 1.

Post a partial delivery of your product T-FF9## for the order.

2.

Deliver the material to storage location 0001 of plant 1100. Choose movement type 101. Enter the number of your process order.

3.

The system proposes the quantity to be delivered according to the plan. Change the proposed quantity. Deliver only half of the planned quantity. Save your goods receipt posting.

4.

After saving the goods receipt, you can assign a value to the characteristics for the batch produced. Enter a value within the valid value range defined for the material. Hint: In one of the following exercises, you will assign batch characteristic values in an in-process quality inspection. Which warning message does the system issue? ______________________________________________________

5.

Display the header data of your order. Continued on next page

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Write down the following: Total qty Delivered 6.

Which new order status has been set with regard to the partial delivery? ______________________________________________________

7.

Go to the Goods Receipt header data screen. Has the Delivery complete indicator been set? What does this indicator mean? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

8.

Display the stock/requirements list for material T-FF9## in plant 1100. What do you notice? ______________________________________________________ ______________________________________________________ ______________________________________________________ Write down the first two lines: MRP element

MRP element data

Recpt/Reqd qty

Available quantity

Task 6: 1.

Post another partial delivery for your product T-FF9##.

2.

Deliver the material to storage location 0001 of plant 1100. Select movement type 101. Enter the number of your process order.

3.

The system proposes the quantity still to be delivered according to the plan. Continued on next page

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Change the proposed quantity. Deliver only half of the quantity still to be delivered according to the plan. In deviation from the plan, you do not expect any further deliveries. For this reason, you set the Delivery completed indicator (D) when you enter the goods receipt. Save your goods receipt posting. After saving, the system again displays the values you have assigned to the batch characteristics in exercise 5-4. Which warning message does the system issue? ____________________________________________________ ____________________________________________________ ____________________________________________________ 4.

Display the header data of your order. Write down the following: Total qty Delivered

5.

Which new order status has been set with regard to the second delivery? ______________________________________________________

6.

Go to the Goods Receipt header data screen. Check whether the system has set the Delivery completed indicator. ______________________________________________________

7.

Display the stock/requirements list for material T-FF9## in plant 1100. What do you notice? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________


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Task 7: 1.

An enormous remaining quantity is available in your production line. Post another delivery for your product T-FF9##.

2.

Deliver the material to storage location 0001 of plant 1100. Select movement type 101. Enter the number of your process order.

3.

The system proposes the quantity still to be delivered according to the plan. The total of the remaining quantity and the quantity still to be delivered is 20 L greater than the planned quantity to be produced. Increase the proposed quantity by 20 L. Save your goods receipt posting.

4.

Which setting determines that an overdelivery is allowed? ______________________________________________________ ______________________________________________________

5.


6.

Display the costs incurred by the order. What do you notice? ______________________________________________________

7.


GMov

Mat. doc. MvT

SLoc

Batch


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Material

8.

GMov

Mat. doc. MvT

SLoc

Batch

Display the stock overview for material T-FF9##.

Task 8: Goods receipt posting using process messages (tasks 8 to 13) 1.

Note: The following exercise aims at illustrating goods receipt posting using process messages by having you maintain a PI sheet with reference to the master recipe T-RC9#. In this scenario, we want you to post the goods receipt and at the same time make activity confirmations in the PI sheet. Some of the process instructions have been created for control recipe destination FX. You must maintain the process instruction for the goods receipt directly in the recipe. Therefore, make the following changes in your master recipe:

2.

Replace the control recipe destination assigned to all phases with the new destination FX.

3.

On the process instruction overview, add process instruction category FE_PROD as item 20 of phase 220. Save your recipe.

Task 9: 1.

Create a process order of order type PO## for material T-FF9## in plant 1100. Enter 1000 L as the quantity to be produced. Enter Today +2 months as the basic start date.

2.


3.

Save the order and write down the order number: ______________________________________________________ Continued on next page

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Task 10: 1.


Task 11: 1.

Find and maintain the PI sheet. In the last phase, you can report the quantity of the fertilizer produced. By executing your signature at the end of the PI sheet, the messages on the activities (PI_PHCON), goods issues (PI_CONS), and good receipt (PI_PROD) are transferred to the message monitor.

Task 12: 1.

Go to the message monitor and analyze the messages of message category PI_PROD that were created while you maintained the PI sheet. Send the messages.

Task 13: 1.


2.


3.

Go to the Goods Receipt header data screen. Check whether the system has set the Delivery completed indicator. ______________________________________________________

488

4.

Display the costs incurred by the order.

5.

Display the goods movement list in the process order.

6.

Display the stock overview for material T-FF9##.

7.

Display the stock/requirements list for material T-FF9## in plant 1100.


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Solution 35: Goods Receipt Task 1: 1.

Which options do you have to post goods receipts for process orders? Which business transactions are triggered by a goods receipt posting? Notes: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on goods receipt, see the page “Goods Receipt” in your participant handbook.

Task 2: Manual goods receipt postings (tasks 2 to 7) 1.

Display the stock overview for your product T-FF9##. What stock quantities are available? ___________________________________________________________ a)

Logistics → Materials Management → Inventory Management → Environment → Stock → Stock Overview Material: T-FF9## Program → Execute or choose Execute There should be a stock of 1000 L available for material T-FF9##. The available quantity of 1000 L comes from the automatic goods receipt of the previous unit. The process order is not displayed in the stock/requirements list anymore due to the final delivery.


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Task 3: 1.

Display the stock/requirements list for material T-FF9## in plant 1100. If you have done the exercises in the previous units as described, the following data should be displayed: T-FF9## Date

MRP element

MRP element data

Recpt/Reqd qty

Available quantity

Today

STOCK

Tomorrow

PR-ORD

Order no. / PO##

1000

2000

Tomorrow + 1 week

PR-ORD

Order no. / PO##

1000

3000

Tomorrow + 2 weeks

PR-ORD

Order no. / PO##

1000

4000

Tomorrow + 3 weeks

PR-ORD

Order no. / PO##

1000

5000

Tomorrow + 4 weeks

PR-ORD

Order no. / PO##

1000

6000

1000

Hint: In the following exercises, only the process order that is chronologically first will be taken into account. This is the order for which you have made goods issue postings and confirmations in the previous units. The available quantity of 1000 L comes from the automatic goods receipt of the previous unit. The process order is not displayed in the stock/requirements list anymore due to the final delivery. a)

(…) → Process Order → Environment → Stock/Requirements List Material: T-FF9## Plant: 1100 Enter


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Task 4: 1.

Display the process order that is chronologically first from the stock/requirements list. a)

2.

Position the cursor on the process order that is chronologically first and choose the Display element icon.

Go to the Goods Receipt header data screen. Which settings have been made with regard to the delivery tolerances of a goods receipt for the order? Underdelivery Overdelivery Unlimited overdelivery a)

3.

On the order header, choose the Goods receipt tab. Underdelivery

0

Overdelivery

0

Unlimited overdelivery

X

Describe what these settings control in a tolerance check. ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

For information on these settings, see the page “„Underdelivery and Overdelivery” in your participant handbook. In addition, use the field help (F1) for information on the relevant fields.

4.

Where do you make the settings for the tolerance check of an order? ______________________________________________________ a)

5.

The settings for the tolerance check are defined on the Work Scheduling view of the material master record.

Display the Work Scheduling view for your product T-FF9## in the material master record for plant 1100.


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Compare the tolerance data defined on this view with the data in your process order. a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-FF9## Enter Choose Work Scheduling. Enter Go to plant 1100. Enter Underdely tol.

0

Overdely. tol.

0

Unltd overdel.

X

Task 5: 1.

Post a partial delivery of your product T-FF9## for the order. a)

2.

(…) → Process Order → Environment → Material Movement → Post Material to Stock

Deliver the material to storage location 0001 of plant 1100. Choose movement type 101. Enter the number of your process order. a)

Movement type: 101 Order number (of the order that is chronologically first): Plant: 1100 Storage location: 0001

3.

The system proposes the quantity to be delivered according to the plan. Change the proposed quantity. Deliver only half of the planned quantity.


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Save your goods receipt posting. a)

Choose Enter. The Goods Receipt for Order: Selection Screen appears.. The system proposes the quantity to be delivered according to the plan (1000 L). Change the proposed quantity. Deliver only half of the planned quantity (500 L). Save your goods receipt posting.

4.

After saving the goods receipt, you can assign a value to the characteristics for the batch produced. Enter a value within the valid value range defined for the material. Hint: In one of the following exercises, you will assign batch characteristic values in an in-process quality inspection. Which warning message does the system issue? ______________________________________________________ a)

The Goods Receipt for Order: Classification screen appears. You can assign a value to the characteristics for the batch produced. Enter a value within the valid value range defined for the material and choose Back. The system issues the following warning message: Deficit of order quantity 500 L. Choose Enter to confirm the warning. The system posts the goods receipt.

5.

Display the header data of your order. Write down the following: Total qty Delivered a)

(…) Process Order → Display Total qty

1000

Delivered

500 Continued on next page

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6.

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Which new order status has been set with regard to the partial delivery? ______________________________________________________ a)

7.

PDLV Partially delivered

Go to the Goods Receipt header data screen. Has the Delivery complete indicator been set? What does this indicator mean? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

Goods receipt tab page The Delivery completed indicator has not been set. For information on the Delivery completed indicator, see the page “„Goods Receipt” in your participant handbook.

8.

Display the stock/requirements list for material T-FF9## in plant 1100. What do you notice? ______________________________________________________ ______________________________________________________ ______________________________________________________ Write down the first two lines:


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MRP element

a)

MRP element data

Recpt/Reqd qty

Available quantity

(…) → Process Order → Environment → Stock/Requirements List Material: T-FF9## Plant: 1100 The planned quantity of goods received has been reduced by the quantity delivered to stock. The plant stock has been increased by the quantity delivered to stock. MRP element

MRP element data

Rec./reqd. qty

Available quantity

STOCK PR-ORD

1 500 Order no. / PO##

500

2 000

Task 6: 1.

Post another partial delivery for your product T-FF9##. a)

2.


Deliver the material to storage location 0001 of plant 1100. Select movement type 101. Enter the number of your process order. a)

3.

Movement Type:

101

Order:

Order number

Plant:

1100

Storage location:

0001

The system proposes the quantity still to be delivered according to the plan. Change the proposed quantity. Continued on next page

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Deliver only half of the quantity still to be delivered according to the plan. In deviation from the plan, you do not expect any further deliveries. For this reason, you set the Delivery completed indicator (D) when you enter the goods receipt. Save your goods receipt posting. After saving, the system again displays the values you have assigned to the batch characteristics in exercise 5-4. Which warning message does the system issue? ____________________________________________________ ____________________________________________________ ____________________________________________________ a)

The system proposes the quantity yet to be delivered according to the plan (500 L). Change the proposed quantity. Deliver only half of the quantity yet to be delivered according to the plan (250 L). Set the Delivery completed indicator: XE Save your goods receipt posting. The system again displays the values you have assigned to the batch characteristics in exercise 5-4. Choose Back. The system issues the following warning messages: Batch was already posted in stock Quantity is 250 L less than the order quantity The item is marked as Delivery completed Choose Enter to confirm the warnings. The system posts the goods receipt.

4.

Display the header data of your order. Write down the following:


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Total qty Delivered a)

5.


1000

Delivered

750

Which new order status has been set with regard to the second delivery? ______________________________________________________ a)

6.

DLV Delivered

Go to the Goods Receipt header data screen. Check whether the system has set the Delivery completed indicator. ______________________________________________________ a)

Goods receipt tab page The Delivery completed indicator has been set.

7.

Display the stock/requirements list for material T-FF9## in plant 1100. What do you notice? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

(…) → Process Order → Environment → Stock/Requirements List Material: T-FF9## Plant: 1100 Due to the Delivery completed indicator, the process order has disappeared from the list. The plant stock has been increased by the quantity delivered to stock. MRP element

MRP element data

Rec./reqd. qty

STOCK

Available qty 1 750


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Task 7: 1.

An enormous remaining quantity is available in your production line. Post another delivery for your product T-FF9##. a)

2.


Deliver the material to storage location 0001 of plant 1100. Select movement type 101. Enter the number of your process order. a)

3.

Movement type:

101

Order:

Order number

Plant:

1100

Storage location:

0001

The system proposes the quantity still to be delivered according to the plan. The total of the remaining quantity and the quantity still to be delivered is 20 L greater than the planned quantity to be produced. Increase the proposed quantity by 20 L. Save your goods receipt posting. a)

The system proposes the quantity yet to be delivered according to the plan (250 L). The total of the remaining quantity and the quantity still to be delivered is 20 L greater than the planned quantity to be produced. Increase the proposed quantity by 20 L (total = 270 L). Select the goods receipt item and save the goods receipt posting.

4.

Which setting determines that an overdelivery is allowed? ______________________________________________________ ______________________________________________________ a)

5.

The Unlimited indicator on the Goods Receipt header data screen determines that an overdelivery is allowed.

Display the header data of your order. Write down the following: Continued on next page

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Total qty Delivered a)

6.


1000

Delivered

1020

Display the costs incurred by the order. What do you notice? ______________________________________________________ a)

Goto → Costs → Analysis Due to the material delivery of product T-FF9## the process order has been credited.

7.


GMov

Mat. doc. MvT

SLoc

Batch


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Material

a)

GMov

SCM340

Mat. doc. MvT

SLoc

Batch

On the order header, choose Goto → Lists → Documented Goods Movements Choose layout /SCM340 in the order information system.

8.

Material

GMov

Mat. doc.

MvT

SLoc

Batch

T-RF7##

1

Doc.no.

261

0002

T-RF7##

1

Doc.no.

261

0002

T-RF9##

1

Doc.no.

261

0002

T-RF9##

1

Doc.no.

261

0002

T-RI5##

2

Doc.no.

261

0002

Batch

T-FF9##

4

Doc.no.

101

0001

Batch

T-FF9##

4

Doc.no.

101

0001

Batch

T-FF9##

4

Doc.no.

101

0001

Batch

Display the stock overview for material T-FF9##. a)

Logistics → Materials Management → Inventory Management → Environment → Stock → Stock Overview Material: T-FF9## Program → Execute

Task 8: Goods receipt posting using process messages (tasks 8 to 13) 1.

Note: The following exercise aims at illustrating goods receipt posting using process messages by having you maintain a PI sheet with reference to the master recipe T-RC9#. In this scenario, we want you to post the goods receipt and at the same time make activity confirmations in the PI sheet. Continued on next page

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Some of the process instructions have been created for control recipe destination FX. You must maintain the process instruction for the goods receipt directly in the recipe. Therefore, make the following changes in your master recipe: a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Change Recipe Group: T-RC9##

2.

Replace the control recipe destination assigned to all phases with the new destination FX. a)

3.

See description

On the process instruction overview, add process instruction category FE_PROD as item 20 of phase 220. Save your recipe. a)

Double-click control phase number 220 on the operation overview. Choose the Process instructions tab. Enter process instruction FE_PROD as item 20. Save your recipe.

Task 9: 1.

Create a process order of order type PO## for material T-FF9## in plant 1100. Enter 1000 L as the quantity to be produced. Enter Today +2 months as the basic start date. a)

Logistics → Production Process → Process Order → Process Order → Create → With Material Material number: T-FF9## Production plant: 1100 Process order type: PO## Enter Total qty: 1,000 L Start: Today +2 months Enter Continued on next page

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2.


3.

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See description

Task 10: 1.


Logistics → Production-Process → Process Management → Control Recipe → Control Recipe Monitor Process order: Order number

Task 11: 1.

Find and maintain the PI sheet. In the last phase, you can report the quantity of the fertilizer produced. By executing your signature at the end of the PI sheet, the messages on the activities (PI_PHCON), goods issues (PI_CONS), and good receipt (PI_PROD) are transferred to the message monitor. a)


Task 12: 1.

Go to the message monitor and analyze the messages of message category PI_PROD that were created while you maintained the PI sheet.


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Logistics → Production - Process → Process Management → Message → Message Monitor Process Order: Order number Choose Enter. The Process Message Monitor: Messages screen appears. By double-clicking a message you can display the message characteristics. Send the messages.

Task 13: 1.


2.


Display the header data of your order. Write down the following: Total qty Delivered a)

3.

No instruction required

Go to the Goods Receipt header data screen. Check whether the system has set the Delivery completed indicator. ______________________________________________________ a)

Choose the Goods receipt tab in the order header. The Delivery completed indicator is set.

4.

Display the costs incurred by the order. a)

5.


Display the goods movement list in the process order. a)

On the order header, choose Goto → Lists → Documented goods movements.


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6.

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Display the stock overview for material T-FF9##. a)

Logistics → Materials Management → Inventory Management → Environment → Stock → Stock Overview Material: T-FF9## Program → Execute

7.

Display the stock/requirements list for material T-FF9## in plant 1100. a)

Logistics → Production - Process → Process Order → Environment → Stock/Requirements List Material: T-FF9## Plant: 1100 Enter

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Lesson Summary You should now be able to: • Perform goods receipt postings for process orders manually using the corresponding ECC transactions • Perform goods receipt postings for process orders using process messages from within the PI sheet

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Lesson: Order Settlement Lesson Overview This lesson informs you about the principle of order settlement.


Settle a process order and describe the general principle of order settlement

Business Example After you post a goods receipt, the order must be exempted of actual costs (debits) so that the order can later be deleted. This credit to the order is an internal activity of Controlling. It is executed using the Settlement function. This function is usually executed monthly with a background job.

Order Closing: Order Settlement

Figure 95: Order Closing: Order Settlement

Order-related cost object controlling • •

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To be able to settle a process order, it must have the status Delivered. Order settlement is a prerequisite for order archiving and deletion.


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Lesson: Order Settlement

Settlement Rules

Figure 96: Settlement Rules

The system automatically assigns a settlement rule to the process order during creation. This assignment is carried out by a default rule defined in Customizing (order type-dependent parameters). The settlement rule covers one or several distribution rules for the process order. The distribution rule consists of a settlement receiver, a settlement share, and a settlement type. Through the settlement receiver, you determine which object is used for settling the actual costs of the process order. By means of the settlement share, you determine the percentage/equivalence number used to distribute the costs to individual settlement receivers. The settlement type is used to determine whether all costs incurred by the order are settled (total settlement) or whether periodic settlement is to be carried out for the order. For make-to-order production, the sales order is automatically defined as the settlement receiver.

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Cost Debit / Credit (Order-Related COC)

Figure 97: Cost Debit / Credit (Order-Related COC)

The manner in which a process order is credited and debited depends on the variant of cost object controlling (COC) selected in Controlling. Both order-related and product-related cost object controlling is possible. Order settlement credits the order. Settlement is usually periodic. It is controlled via a settlement profile. It makes sense to use order-related COC for the following: • • • • • •

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

For in-house production of materials, it is generally best to use standard price control.

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Cost Debit / Credit (Product-Related COC)

Figure 98: Cost Debit / Credit (Product-Related COC)

Settlement is period-oriented based on the costs of the product cost collector. In this case, there is no order settlement for the individual process order. The process order also does not have any costs or any settlement rule in this case. It makes sense to use product-related COC for the following: Make-to-stock production Repetitive manufacturing and mass manufacturing Sales order controlling only in profitability analysis

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Exercise 36: Order Settlement Exercise Objectives After completing this exercise, you will be able to: • Settle a process order and analyze the settlement result

Business Example After a goods receipt was posted for a material, the relevant process order must be exempted of actual costs (debits) so that the order can later be deleted. This credit to the process order is an internal activity of Controlling. It is executed using the “Settlement” function. This function is usually executed monthly in a background program. As the production scheduler or foreman, you do not have to execute any activities here. You should be aware, however, that this function is to be executed before the orders are deleted.

Task 1: 1.

Display, for example, the process order for material T-FF9## that you last processed in the previous topic on goods receipts. Hint: You have written down the order number from the relevant exercise.

2.

Display the costs incurred by the order.

3.

As a result of which business transactions did the system debit the order with actual costs? ______________________________________________________ ______________________________________________________ As a result of which business transaction did the system credit the order? ______________________________________________________

4.

Display the settlement rule for the process order. To which settlement receiver are the process order costs assigned during the settlement procedure? ______________________________________________________ Continued on next page

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Task 2: 1.

Display the Accounting 1 view of the material master record for material T-FF9## in plant 1100.

2.

Write down the following: Price control Moving price Standard price Total stock Total value

Task 3: 1.

Settle your process order in individual processing.

2.

Your plant 1100 is assigned to controlling area 1000. Enter the number of the present month (for example, 8 for August) as the settlement period and the present year as the fiscal year.

3.

Display the detail list for settlement and write down the settlement sender and settlement receiver. Sender: __________________________________________________ Receiver: __________________________________________________

4.

Display the detail data about the sender and receiver. Write down the following: Sender: Cost element

Value/CAC


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* Receiver

Value/CAC

Cost element

Display the detail data for individual debits (cost elements). 5.

Display the list of the accounting documents generated. Display the accounting document. The amount settled is posted to a price difference account.

6.

Exit the order settlement. Display the accounting document in financial accounting. Only select your documents for the current creation date. You find documents for goods issues (document type WA), goods receipts (WE), and settlement (SA).

Task 4: 1.

Display the costs incurred by your process order. Describe how order settlement affected the order costs: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 5: 1.

Display the Accounting 1 view of the material master record for material T-FF9## in plant 1100.

2.

Write down the following:


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Price control Moving average price Standard price Total stock Total value 3.

Why did order settlement not affect the total value of the material stock? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

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Solution 36: Order Settlement Task 1: 1.

Display, for example, the process order for material T-FF9## that you last processed in the previous topic on goods receipts. Hint: You have written down the order number from the relevant exercise. a)

Logistics → Production - Process → Process Order → Process Order → Display Process order: Order number

2.

Display the costs incurred by the order. a)

3.


As a result of which business transactions did the system debit the order with actual costs? ______________________________________________________ ______________________________________________________ As a result of which business transaction did the system credit the order? ______________________________________________________ a)

As a result of the material withdrawals and confirmations the order was debited with the corresponding material costs and production costs. When the batch you produced was delivered to stock, the order was credited.

4.

Display the settlement rule for the process order. To which settlement receiver are the process order costs assigned during the settlement procedure? ______________________________________________________ a)

On the order header, choose Header → Settlement rule. In our example (make-to-stock production), the order costs have been fully settled to material T-FF9##.


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Task 2: 1.

Display the Accounting 1 view of the material master record for material T-FF9## in plant 1100. a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-FF9## Enter Go to the Accounting 1 view. Enter Choose plant 1100. Enter

2.

Write down the following: Price control Moving price Standard price Total stock Total value a) Price control

S

Moving price

Moving price

Standard price

Standard price

Total stock

Stock

Total value

Stock quantity * standard price

Task 3: 1.

Settle your process order in individual processing. a)

2.

(…) → Process Order → Period-End Closing → Settlement → Individual Processing

Your plant 1100 is assigned to controlling area 1000. Continued on next page

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Enter the number of the present month (for example, 8 for August) as the settlement period and the present year as the fiscal year. a)

Controlling area: 1000 Order: Order number Settlement period: Current month number Fiscal year: Current year Processing type: Automatic Process control: No test run Settlement → Execute or choose Execute

3.

Display the detail list for settlement and write down the settlement sender and settlement receiver. Sender: __________________________________________________ Receiver: __________________________________________________ a)

The Actual Settlement Order Basic List screen appears. Choose the Detail lists icon. The Actual Settlement Order Detail List screen appears. Sender: ORD Order number Fertilizer, liquid, form SX Receiver: MAT 1100/T-FF9##

4.

Display the detail data about the sender and receiver. Write down the following: Sender: Cost element

Value/CAC

*


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Receiver

Value/CAC

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Cost element

Display the detail data for individual debits (cost elements). a)

To display the detail data about the sender, position the cursor on the corresponding line in the list and choose Sender. The Actual Settlement Order Debit Sender screen appears. You can display details for individual debits (= cost elements) by positioning the cursor on a table line and choosing the Choose detail icon. To display the detail data about the receiver, position the cursor on the corresponding line in the list and choose Receiver. The Actual Settlement Order Debit Receiver screen appears.

5.

Display the list of the accounting documents generated. Display the accounting document. The amount settled is posted to a price difference account. a)

On the Actual Settlement Order Detail List screen, choose Accounting documents. On the List of Documents in Accounting screen, choose Accounting documents.

6.

Exit the order settlement. Display the accounting document in financial accounting. Only select your documents for the current creation date.


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You find documents for goods issues (document type WA), goods receipts (WE), and settlement (SA). a)

Accounting → Financial Accounting → General Ledger → Document → Display The Display Document: Initial Screen appears. Choose Document List. The Document List screen appears. Company code: 1000 Entry date: Today X Own documents only Execute icon.

Task 4: 1.

Display the costs incurred by your process order. Describe how order settlement affected the order costs: ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

(…) Process Order → Display Goto → Costs → Analysis After order settlement, the process order is completely credited. Its balance is 0.


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Task 5: 1.

Display the Accounting 1 view of the material master record for material T-FF9## in plant 1100. a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-FF9## Enter Go to the Accounting 1 view. Enter Go to plant 1100. Enter

2.

Write down the following: Price control Moving average price Standard price Total stock Total value a)

3.

Price control

S

Moving average price

New price after settlement

Standard price

Standard price

Total stock

Stock

Total value

Stock quantity * standard price

Why did order settlement not affect the total value of the material stock? ______________________________________________________ ______________________________________________________ ______________________________________________________


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______________________________________________________ a)

Due to price control S, the inventory valuation is carried out according to the standard price. The standard price is not changed by a settlement. The settlement results are taken into account in the moving average price.

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Lesson Summary You should now be able to: • Settle a process order and describe the general principle of order settlement

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Lesson: Archiving and Deleting

Lesson: Archiving and Deleting Lesson Overview This lesson informs you about the general process of order reorganization.


Describe the process of process order reorganization

Business Example Process orders whose processing was completed in your area (goods receipt posted) must be archived and deleted after a period defined in Customizing, to ensure that the database volume is limited and does not go on increasing over time. The system administrator in your company archives and deletes process orders. He or she usually starts several background jobs per month for this purpose. In this unit, you will get an overview of the process and requirements for order reorganization.

Order Closing: Archiving and Deleting

Figure 99: Order Closing: Archiving and Deleting

The process order must be settled before it can be archived and deleted. When setting up the system for production in compliance with GMP, you can also define that as a prerequisite for order archiving and deletion a batch record must be created and approved.

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Reorganization: Procedure

Figure 100: Reorganization: Procedure

The reorganization of orders in the ECC System comprises the following stages: • • • •

Activating the deletion flag in the order Activating the deletion indicator in the order Execution of an archiving run Execution of a deletion run

The physical deletion/archiving takes place after some requirements have been checked. You can delete orders individually or in mass deletion. You can use the retrieval function to display archived and deleted orders in the ECC System. The deletion and archiving functions for the process order use the central ECC System archiving tools. This enables you to use various different archiving systems. In archive administration, you can create and display an index list of archived process orders.

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Lesson: Archiving and Deleting

Archiving and Deleting: Prerequisites

Figure 101: Archiving and Deleting: Prerequisites

You can only archive an order if you have activated the deletion flag manually or automatically (that is, using a background report). • •

Prerequisite: The order is delivered or technically completed, there are no payables or Future change records from confirmations; cost balance = 0. To be able to settle a process order, it must have the status Delivered (DLV) or Technically completed (TABG).

• •

If production is in compliance with GMP, the batch record for the order must also be archived (status BRAR Batch record archived). The deletion flag can be removed.

Once a first residence time is over, the deletion flag is activated for orders marked for deletion in a background job. • •

Prerequisite: The deletion flag must be set. Once the deletion flag has been set, you can no longer change the order.

After a second residence time has passed, the orders are taken from the corresponding files in the ECC System and are transferred to the respective operating system. When the files have been transferred successfully, the data is deleted in the ECC System. •

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Lesson Summary You should now be able to: • Describe the process of process order reorganization

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Unit Summary

Unit Summary You should now be able to: • Perform goods receipt postings for process orders manually using the corresponding ECC transactions • Perform goods receipt postings for process orders using process messages from within the PI sheet • Settle a process order and describe the general principle of order settlement • Describe the process of process order reorganization

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Unit Summary

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Test Your Knowledge

Test Your Knowledge

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1.

How can you make goods receipt postings for process orders?

2.

Name the two variants of cost object controlling for order-related production.

3.

Name the prerequisites for being able to archive an order.


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Answers 1.

How can you make goods receipt postings for process orders? Answer: You can post goods receipts manually by using Inventory Management transactions or by sending process messages from the PI sheet or a process control system. You can also post a goods receipt automatically during confirmation.

2.

Name the two variants of cost object controlling for order-related production. Answer: • •

3.

Order-related cost object controlling Product-related cost object controlling

Name the prerequisites for being able to archive an order. Answer: • • •

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Status DLV (delivered) or TECO (technically complete) Cost balance = 0 (order settlement) Production in compliance with GMP: status BRAR (batch record archived)


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Unit 9 Principle of Process Management (II) Unit Overview Topics: • • • • •

Process instructions, control recipes, and process messages Link to process control systems Elements of PI sheets Manufacturing data access SAP OPC data access (SAP ODA)

Unit Objectives After completing this unit, you will be able to: • • • • • • • • • • • • • •

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Name the functions of process management Name the alternative maintenance options for process instructions Describe the relationship between process instructions, control recipes, and process messages Describe how a control recipe is created from process instructions Describe how the information of process instructions is displayed in a PI sheet Describe how process messages are created Name the message destination types that are available Name the most important predefined message categories in the standard system Describe the principle of how control recipes can be transferred to a process control system Name the process instruction types available for communicating with process control systems and explain their functions Describe typical scenarios for the data exchange between the ECC System and a process control system Name the important elements and functions of the PI sheet Explain the principle of the Manufacturing Data Access internal interface Name the predefined services in the environment of PP-PI


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•

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Explain the basic concepts of OPC and SAP ODA.

Unit Contents Lesson: Process Management - Overview ..................................533 Lesson: Process Instructions, Control Recipes, and Process Messages ........................................................................536 Exercise 37: Process Instructions, Control Recipes, and Process Messages....................................................................549 Lesson: Link to Process Control Systems ...................................591 Lesson: Elements of PI sheets................................................596 Lesson: Manufacturing Data Access ........................................607 Lesson: SAP OPC Data Access ..............................................610

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Lesson: Process Management - Overview

Lesson: Process Management - Overview Lesson Overview This lesson gives you an overview of the process management functions.


Name the functions of process management

Business Example You want to use process management to represent certain processes of process manufacturing. You will first get an overview of the functions of process management.

Process Management

Figure 102: Process Management

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Process management is the interface between PP-PI and the systems involved in process control. Due to its flexible structure, it can be linked to fully automated, partially automated, and manually operated lines. Process management includes the following functions: •

Communication with the process control level using the PI-PCS interface or using PI sheets: –

•

Receiving control recipes with process instructions from released process orders. The process instructions define, for example, the process steps to be executed and the process data to be confirmed (using process messages) in detail. – Manual processing: Displaying control recipes in natural language in the form of PI sheets that can be displayed and maintained on the screen by the process operator. – Automatic processing: Transferring control recipes to process control systems. Data is exchanged using the PI-PCS interface. . – Receiving, checking, and sending process messages with actual process data from the PI sheet or the process control system. Data is exchanged from the external System using the PI-PCS interface. Reading and writing data points and events with the function SAP OPC Data Access (SAP ODA) using the OPC server of the ECC System. – –

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Reading and writing with a PI Sheet. Reading using the function automatic creation of process messages.


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Lesson: Process Management - Overview

Lesson Summary You should now be able to: • Name the functions of process management

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Lesson: Process Instructions, Control Recipes, and Process Messages Lesson Overview This lesson informs you about the connectivity of process instructions, control recipes and process messages.

Lesson Objectives After completing this lesson, you will be able to: • • • • • • •

Name the alternative maintenance options for process instructions Describe the relationship between process instructions, control recipes, and process messages Describe how a control recipe is created from process instructions Describe how the information of process instructions is displayed in a PI sheet Describe how process messages are created Name the message destination types that are available Name the most important predefined message categories in the standard system

Business Example To be able to use the process management for controlling process manufacturing, you must familiarize yourself with the alternative maintenance options for process instructions and the connectivity of process instructions, control recipes and process messages.

Alternatives for Process Instruction Maintenance Alternative 1 (all releases) • • • •

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Presetting process instruction types in Customizing Maintaining process instructions on the basis of copied process instruction types for the phases of the recipe / process order Assigning the control recipe destinations to the phases Defining process instructions to be generated for the control recipe destinations in Customizing


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Lesson: Process Instructions, Control Recipes, and Process Messages

Alternative 2 (from SAP ECC ERP and SCM Extension 2.00) • • •

Maintaining all process instructions in XSteps (execution steps) in the XStep Editor of the recipe / process order Option to copy or reference standard XSteps from the standard XStep repository Option to copy or reference standard XSteps from the standard XStep repository

Creating Control Recipes: Alternative 1

Figure 103: Creating Control Recipes: Alternative 1

Process instructions are structures used to transfer data or instructions from ECC process manufacturing to process control. They are assigned to the phases of the master recipe or process order, and to the control recipe destinations (in Customizing). Users define process instructions according to the target system requirements. The process management groups the process instructions to control recipes and transfers these to the control recipe destinations that are stored in the process order. Control recipes contain all the information that process control needs to execute a process order. The system creates one control recipe for each control recipe destination of a process order.

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You can create control recipes for the following destination types: • • •

Process control systems in automated production lines Process operators in manually operated production lines In the second case, the control recipe is displayed in natural language in the form of a PI sheet that can be maintained by the process operator.

Creating Control Recipes: Alternative 2

Figure 104: Creating Control Recipes: Alternative 2

Alternative 2: Maintaining process instructions for XSteps •

From SAP R/3 ERP and SCM Extension 2.00 (EA_APPL_2.00), the data for the process management can alternatively be maintained in the form of XSteps (execution steps). Using XSteps enables you to maintain process instructions in the form of reusable and referenceable modules. A Standard XStep Repository with version management is available.

Example Scenario for Alternative 1 • • •

538

Maintaining process instructions Generating process instructions PI sheet


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Maintaining Process Instructions: Example Scenario 1:

Figure 105: Maintaining Process Instructions: Example Scenario 1:

This example shows the process instructions for the master recipe Fertilizer, liquid, form SX. Process instructions that are specific to the production process of the fertilizer are maintained for the phases of the recipe. Process instruction INSTR has been defined for the first phase 110. It contains a process-specific instruction text for the PI sheet. The control recipe destination FE is assigned to the phases of the recipe. Process instructions that are specific to the control recipe destination and are always required in certain positions of a control recipe or PI sheet, regardless of a particular production process or master recipe, are maintained for the control recipe destination (in Customizing). When you create the control recipe, the process instructions are generated in the specified positions of the control recipe.

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Generating Process Instructions: Example Scenario 1

Figure 106: Generating Process Instructions: Example Scenario 1

This example shows a process order that was created based on the master recipe Fertilizer, liquid, form SX. The order was released and the control recipe was created. Take a look at the first phase 110 of the order. In addition to the process instruction INSTR from the recipe, the system generated the process instructions defined for the control recipe destination at the specified positions. Note: • •

540

In this example, the system did not generate the process instruction SEQDEF because the phase did not have a preceding phase. The system generated the process instruction FE_CONS twice because two material components are assigned to phase 110.


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PI Sheet: Example Scenario 1

Figure 107: PI Sheet: Example Scenario 1

The graphic shows the PI sheet for the process instructions in phase 110 of the process order. The process instruction PHTEXT creates the short text in phase 110. The process instruction INSTR creates the control instruction with a safety note. The process instructions FE_PHSTS and FE_PHSTE each create an input field for executing a signature. The process instructions FE_CONS create input fields to confirm the charged material component quantities.

Example Scenario for Alternative 2 (XSteps) • • •

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Maintaining XSteps Generating XSteps PI sheet


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Maintaining XSteps: Example Scenario 2

Figure 108: Maintaining XSteps: Example Scenario 2

Generating XSteps: Example Scenario 2

Figure 109: Generating XSteps: Example Scenario 2

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PI Sheet: Example Scenario 2

Figure 110: PI Sheet: Example Scenario 2

Generating Process Messages: Scenarios 1 & 2

Figure 111: Generating Process Messages: Scenarios 1 & 2

When you enter a signature at the phase start, the system creates a process message that reports the start of phase 110 to the process order.

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When you enter the charged actual quantity, the system creates a process message that triggers a material consumption posting in inventory management. When you enter a signature at the phase end, the system creates a process message that reports the end of phase 110 to the process order.

Generating Process Messages: Scenarios 1 & 2

Figure 112: Generating Process Messages: Scenarios 1 & 2

The graphic shows process message creation using the actual quantity recording of material T-RF700 as an example. The message contains the order number, date and time, material number, charged material quantity, and the unit of measure. When creating the PI sheet, the system determines the order number, the material number, and the unit of measure. When you enter the actual quantity, the system automatically records the date and time. When you enter the charged actual quantity, the process message data is complete. The message can then be sent to the appropriate message destination. This would be the Goods issue posting function module in our example.

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Types of Message Destinations

Figure 113: Types of Message Destinations

Process messages can be sent to one or more destinations for further processing. They can be sent to the following destination types, for example: • • • • •

ECC function module User of the SAPoffice mail system ABAP tables defined by the user External functions (such as a process control system) An alert category of the SAP Alert Management System

The standard system contains predefined message destinations of the type ECC function module. You can, for example, use these destinations to: • • • •

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Update the control recipe status Report time events for the phases of an order Post goods movements Report inspection results to QM


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Message Categories in the Standard System (I)

Figure 114: Message Categories in the Standard System (I)

The standard system contains a number of predefined message categories enabling you to transfer actual data from process control to the ECC System. You can use these message categories for the following functions: • • • • • •

546

Updating the control recipe status and the corresponding order status Confirming time events Confirming activities Posting a goods issue for the order Posting a goods receipt for the order Reporting summarized measurement results to QM as inspection results


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Message Categories in the Standard System (II)

Figure 115: Message Categories in the Standard System (II)

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Exercise 37: Process Instructions, Control Recipes, and Process Messages Exercise Objectives After completing this exercise, you will be able to: • Name the two alternative maintenance options for process instructions • Describe for each maintenance option how a control recipe is created in a process order • Describe for each maintenance option how the information of process instructions is displayed in a PI sheet • Describe how process messages are created • Name the message destination types that are available • Name important predefined message categories in the standard system

Business Example You will become familiar with the two alternative maintenance options for process instructions. For each of the maintenance options, you examine one example scenario as follows: You will analyze the assignment and maintenance of process instructions for a master recipe. You will create a process order that is based on this master recipe and have another look at the process instructions. In particular, you will analyze the process instructions that are automatically generated when the control recipe is created. You will maintain the PI sheet. You will compare the objects in the PI sheet with the process instructions in the process order. You will then analyze the process messages that the system created while you maintained the PI sheet.

Task 1: 1.

You will name and describe the two alternative maintenance options for process instructions. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Continued on next page

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___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: Alternative 1: Maintaining process instructions in the process instruction overview and for the control recipe destination (exercises 2 to 18) Preparations: Define control recipe destination FE for all phases of your recipe T-RC9##. 1.

Describe the function and maintenance of process instructions with reference to maintenance alternative 1 described in your participant handbook. To which objects can you assign process instructions in this alternative? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 3: 1.

Describe the function of control recipes. How do you create control recipes? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 4: 1.

To which destination types can you send control recipes? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________


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Task 5: 1.

Display the master recipe of recipe group T-RC9##.

2.

Which control recipe destination has been assigned to the phases? _____________________________________________________

3.

Go to the process instruction overview of phase 110 and write down which process instruction has been assigned to the phase. PI

4.

PI type

Type

Description

Display the process instructions that have been assigned to control recipe destination FE and are automatically generated by the system. Write down the destination type. _____________________________________________________ Write down the information displayed about the process instructions in the following table: InstCat

Item

Description

Sequence GenScope Filter


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InstCat

Item

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Description


Task 6: 1.

Create a process order for material T-FF9## in plant 1100. Use process order type PO##. Enter 1000 L as the quantity you want to produce and choose today as the order start date. As a result of the production scheduling profile in the material master record, the system releases the order immediately and creates the control recipe. Save the order and write down the order number. ___________________________________________________________

Task 7: 1.


2.

Display the process instruction overview for phase 110. Write down which process instructions are assigned to the phase in the following table: No. of PI

ProcInstCat

Object type

Description


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No. of PI

3.

ProcInstCat

Object type

Description

Interpret the result of the previous task. To do so, compare the process instructions in the process order with the process instructions assigned to the master recipe T-RC9## and those assigned to control recipe destination FE. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________

Task 8: 1.

Select your control recipe in the control recipe monitor and send it.

Task 9: 1.

Call up the PI sheet that was created by sending the control recipe in the change mode.

2.

Look at the information and input fields displayed for phase 110 in the PI sheet. Try to find out how the process instructions of phase 110 in the process order are related to the various elements in the PI sheet. ProcInstCat

In the PI sheet

PHTEXT FE_PHSTS INSTR FE_CONS


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ProcInstCat

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In the PI sheet

FE_CONS FE_PHSTE

3.

Maintain phase 110 in your PI sheet. Exit the PI sheet. In the message monitor, select the process messages that were created when you maintained the first process steps in the PI sheet.

Task 10: 1.

In the message monitor, select the process messages that were created when you maintained the first process steps in the PI sheet.

2.

Write down the messages that were created. Process Message Category

3.

Display your process order. . . Go to the process instruction overview for phase 110. Go to the process instruction assistant for the four process instructions of types FE_PHSTS, FE_CONS and FE_PHSTE that are allocated to the phase. Write down the following information for the process instructions: a) The process message category that each of them requests b) The input field defined for each of them in the process instruction Solution approach: Process instructions with the process instruction characteristic PPPI_MESSAGE_CATEGORY are used to request process messages. The text of the input characteristic is assigned to the process instruction characteristic PPPI_INPUT_REQUEST. The input characteristic is assigned to the process instruction characteristic PPPI_REQUESTED_VALUE. You can use the F4 input help to determine the name of the input characteristic. Continued on next page

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No. of PI

PI type

Message category

Input characteristic

Description

4.

0000

FE_PHSTS

9999

FE_CONS

9999

FE_CONS

9999

FE_PHSTE

Text

Interpret the result of the previous tasks. To do so, compare the process messages created so far with the input fields that you have maintained for phase 110 in the PI sheet. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________

Task 11: 1.

Write down the destination types to which you can send process messages. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 12: 1.

Which process messages are contained in the standard system and which functions do they have? Continued on next page

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___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 13: 1.

In the message monitor, display the characteristics for the four process messages that the system created. Write down the characteristic values. Process message category PI_PHST Message characteristics


Process message category PI_CONS Message characteristics



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Process message category PI_PHST Message characteristics


Task 14: 1.


2.

Write down the statuses of phase 110. _____________________________________________________

3.

Write down the confirmed dates for phase 110. _____________________________________________________

4.

Write down the confirmed quantities for phase 110. _____________________________________________________

5.

Write down the quantities withdrawn for material components T-RF7## and T-RF9##. _____________________________________________________


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Task 15: 1.

Send the first three messages in the message monitor (PI_PHST, PI_CONS, PI_CONS).

Task 16: 1.


2.

Write down the statuses of phase 110. _____________________________________________________ _____________________________________________________ _____________________________________________________

3.

Write down the confirmed start date for phase 110. Compare the confirmed date and time with the characteristic values of the corresponding process message. _____________________________________________________ _____________________________________________________ _____________________________________________________

4.

Write down the confirmed quantities for phase 110. _____________________________________________________ _____________________________________________________

5.

Write down the quantities withdrawn for material components T-RF7## and T-RF9##. Compare the quantities with the characteristic values of the corresponding process messages. _____________________________________________________ _____________________________________________________ _____________________________________________________

Task 17: 1.

Send the fourth message in the message monitor (PI_PHST).


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Task 18: 1.


2.

Write down the statuses of phase 110. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________

3.

Write down the finish date for phase 110. Compare the confirmed date and time with the characteristic values of the corresponding process message. _____________________________________________________ _____________________________________________________ _____________________________________________________

4.

Write down the confirmed activity for phase 110. How did the system calculate this activity? _____________________________________________________ _____________________________________________________

Task 19: Alternative 2: Maintenance of process instructions in XSteps (exercises 19 to 26) 1.

Describe the principle of the maintenance of process instructions with reference to maintenance alternative 2 described in your participant handbook. To which objects are process instructions assigned in this alternative? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________


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Task 20: 1.

How do you create control recipes in this alternative? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 21: 1.

Go into the master recipe of the recipe group T-RCX9## in the change mode.

2.

Can control recipe destinations be maintained for the phases? _____________________________________________________ Can process instructions be assigned to the phases? _____________________________________________________

3.

Display the profile of the recipe. Write down the profile setting for the process instruction maintenance. Process instruction maintenance: __________________________________ What does this profile parameter define, and how does the setting selected influence the maintenance option for process instructions? Use the F1 help for the field Process instruction maintenance to answer the question. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

4.

Navigate to the XStep Editor of your recipe.

5.

Write down the following for the XStep tree: Description: _________________________________________ Application context: ___________________________________ Continued on next page

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Receiver: _________________________________________ 6.

Write down the following information for the XSteps of the XStep tree: XStep description

7.

Application context

Generation

Which of the above XSteps were created in the recipe, and which were assigned as references to standard XSteps from the standard XStep repository? Standard XSteps: _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ XSteps created in the recipe: _____________________________________________________ _____________________________________________________ _____________________________________________________

8.

The process instructions for the XSteps created in the recipe are maintained in the recipe. Continued on next page

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Describe which process instruction is created with which elements for the XStep control instruction with a safety note. Description of the process instruction: _____________________________________________________ Elements of the process instruction _____________________________________________________ _____________________________________________________ 9.

Simulate the PI sheet. Note: The explosion of the standard XStep references and the complete generation only occur in the process order.

10. The process instructions for the standard XSteps are maintained in the standard XStep repository. Go into the standard XStep repository for plant 1100. 11. In the standard XStep repository, expand the folder Fertilizer production DE. You will find the standard XSteps used in your master recipe. Try to analyze the structures and contents of these standard XSteps. Use the simulation if necessary.

Task 22: 1.

Create a process order for material T-FF9## in plant 1100. Use process order type PO##. Enter 1000 L as the quantity you want to produce and choose today as the order start date. Manually select the production version XSDE to create the order. Immediately after the order is created, the order is released and the control recipe created. Save the order and write down the order number. ___________________________________________________________

Task 23: 1.

Display your process order. Continued on next page

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2.

Display the XSteps of the process order. Note that the following activities occurred when the control recipe was created: - The standard XSteps were exploded - The generation was performed Try to analyze the structures and contents of some of these exploded and generated standard XSteps. Simulate the PI sheet.

Task 24: 1.

Select your control recipe in the control recipe monitor and send it.

Task 25: Call up the PI sheet that was created by sending the control recipe in the change mode. 1.

Look at the information and input fields displayed in the PI sheet. Try to find out how the XSteps of the process order are related to the various elements in the PI sheet.

Task 26: 1.

You can now carry out the following activities corresponding to the above exercises for scenario 1: - Process the PI sheet - Analyze the process messages that the system created while you maintained the PI sheet. - Analyze in which XSteps and in which process instructions of the process order the requirements of these process messages are defined.

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Solution 37: Process Instructions, Control Recipes, and Process Messages Task 1: 1.

You will name and describe the two alternative maintenance options for process instructions. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the maintenance options for process instructions, see the page Options for process instruction management in your participant handbook.

Task 2: Alternative 1: Maintaining process instructions in the process instruction overview and for the control recipe destination (exercises 2 to 18) Preparations: Define control recipe destination FE for all phases of your recipe T-RC9##. 1.

Describe the function and maintenance of process instructions with reference to maintenance alternative 1 described in your participant handbook. To which objects can you assign process instructions in this alternative? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the process instructions, refer to the page Creating Control Recipes: Alternative 1 in your participant handbook.


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Task 3: 1.

Describe the function of control recipes. How do you create control recipes? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on control recipes, refer to the page Creating Control Recipes: Alternative 1 in your participant handbook.

Task 4: 1.

To which destination types can you send control recipes? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on destination types, refer to the page Creating Control Recipes: Alternative 1 in your participant handbook.

Task 5: 1.

Display the master recipe of recipe group T-RC9##. a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Display Recipe Group: T-RC9##

2.

Which control recipe destination has been assigned to the phases? _____________________________________________________ a)

Choose Enter. The operation overview appears. The phases of the recipe are assigned Control recipe destination FE

3.

Go to the process instruction overview of phase 110 and write down which process instruction has been assigned to the phase. Continued on next page

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PI

a)

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PI type

Type

Description

Double-click phase number 110 and choose the Process instructions tab. The following process instruction has been assigned to the phase:

4.

PI

PI type

Type

Description

0010

INSTR

1

Control instruction with note

Display the process instructions that have been assigned to control recipe destination FE and are automatically generated by the system. Write down the destination type. _____________________________________________________ Write down the information displayed about the process instructions in the following table: InstCat

Item

Description



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InstCat

Item

Description


a)

Double-click control recipe destination FE on the operation overview. Type: 4 Transfer to browser-based PI sheet. InstCat

Item

Description

Sequence GenScope Filter SEQDEF

05

At the start of a phase

01 05

For all predecessors No filter

PHTEXT

05


02 00

Only one process instruction No filter

FE_PHSTS

05


03 00


FE_CONS

06


01 01


FE_PHSTE

06

At the start of a phase Continued on next page

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InstCat

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Item

Description

Sequence GenScope Filter 02 00


Task 6: 1.

Create a process order for material T-FF9## in plant 1100. Use process order type PO##. Enter 1000 L as the quantity you want to produce and choose today as the order start date. As a result of the production scheduling profile in the material master record, the system releases the order immediately and creates the control recipe. Save the order and write down the order number. ___________________________________________________________ a)

Logistics → Production - Process → Process Order → Process Order → Create → With Material Material no.: T-FF9## Production plant: 1100 Process order type: PO## Choose Enter. The Create Process Order: Header – General Data screen appears. Enter the following data: Total qty: 1000 L Start: Today Choose Enter. The system copies master recipe T-RC9##, schedules and releases the order, and creates the control recipe. Save your order and write down the order number.


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Task 7: 1.


(…) → Process Order → Display Process order: Order number

2.

Display the process instruction overview for phase 110. Write down which process instructions are assigned to the phase in the following table: No. of PI

a)

ProcInstCat

Object type

Description

Choose Operations. Select phase 110 and choose Process inst.

3.

No. of PI

ProcInstCat

Object type

Description

0000

PHTEXT

1

Short text for phase

0000

FE_PHSTS

2

Phase start with signature

0010

INSTR

1

Control instruction with note

9999

FE_CONS

2

Material consumption (fertilizer prod.)

9999

FE_CONS

2

Material consumption (fertilizer prod.)

9999

FE_PHSTE

2

Phase end with signature

Interpret the result of the previous task. To do so, compare the process instructions in the process order with the process instructions assigned to the master recipe T-RC9## and those assigned to control recipe destination FE. Continued on next page

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_____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

For information on process instructions, see the pages Maintaining process instructions: example scenario 1 and Generating process instructions: example scenario 1 in your participant handbook.

Task 8: 1.

Select your control recipe in the control recipe monitor and send it. a)

Logistics → Production - Process → Process Management → Control Recipe → Control Recipe Monitor Plant: 1100 Process order: Order number Choose Enter. The Control Recipe Monitor: Overview screen appears. Select the control recipe and choose Send. After sending, choose the Refresh icon. The control recipe must now have status Sent.

Task 9: 1.

Call up the PI sheet that was created by sending the control recipe in the change mode. a)

(…) → Process Management → PI Sheet → Find Process order: Order number

2.

Look at the information and input fields displayed for phase 110 in the PI sheet. Try to find out how the process instructions of phase 110 in the process order are related to the various elements in the PI sheet. ProcInstCat

In the PI sheet

PHTEXT


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ProcInstCat

In the PI sheet

FE_PHSTS INSTR FE_CONS FE_CONS FE_PHSTE

a)

3.

The process instructions assigned to phase 110 in the process order are displayed as follows in the PI sheet (see also the page PI Sheet: Example in your participant handbook): ProcInstCat

In the PI sheet

PHTEXT

Phase short text is displayed

FE_PHSTS

Input field for signature to report the phase start

INSTR

Instruction and safety note is displayed

FE_CONS

Input field to report the quantity of material T-RF7## (ammonia) charged

FE_CONS

Input field to report the quantity of material T-RF9## (potassium sulfate) charged

FE_PHSTE

Input field for signature to report phase end

Maintain phase 110 in your PI sheet. Exit the PI sheet.


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In the message monitor, select the process messages that were created when you maintained the first process steps in the PI sheet. a)

Enter your signature to report the start of phase 110. Use your ECC user to sign and the ECC password to confirm your signature. Report the actual quantities of the ingredients ammonia and potassium sulfate charged. The target quantities are set as default values for the actual quantities to be reported. You can change the quantities. Enter your signature to report the end of phase 110. Choose Exit to leave the PI sheet.

Task 10: 1.

In the message monitor, select the process messages that were created when you maintained the first process steps in the PI sheet. a)

(…) → Process Management → Message → Message Monitor Plant: 1100 Process order: Order number

2.

Write down the messages that were created. Process Message Category

a)

Choose Enter. The Process Message Monitor: Messages screen appears. The following messages have been created so far: ProcMessCat PI_PHST PI_CONS PI_CONS PI_PHST

3.

Display your process order. . . Continued on next page

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Go to the process instruction overview for phase 110. Go to the process instruction assistant for the four process instructions of types FE_PHSTS, FE_CONS and FE_PHSTE that are allocated to the phase. Write down the following information for the process instructions: a) The process message category that each of them requests b) The input field defined for each of them in the process instruction Solution approach: Process instructions with the process instruction characteristic PPPI_MESSAGE_CATEGORY are used to request process messages. The text of the input characteristic is assigned to the process instruction characteristic PPPI_INPUT_REQUEST. The input characteristic is assigned to the process instruction characteristic PPPI_REQUESTED_VALUE. You can use the F4 input help to determine the name of the input characteristic. No. of PI

PI type

Message category

Input characteristic

Description 0000

FE_PHSTS

9999

FE_CONS

9999

FE_CONS

9999

FE_PHSTE

a)

Text

(…) → Process Order → Display Process order: Order number Choose Operations. Select phase 110 and choose Process inst. Proceed as follows for the four process instructions of type FE_PHSTS, FE_CONS and FE_PHSTE:


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Select the process instruction you want to display and choose the Details Process Instruction icon. The overview of the process instruction characteristics appears. The following message categories and input fields are assigned to the process instructions: No. of PI 0000

PI type

FE_PHSTS

Message category

PI_PHST

Input characteristic Description

Text

Signature

Signature

Message on phase status 9999

9999

9999

FE_CONS

FE_CONS

FE_PHSTE

Phase start:

PI_CONS

Quantity

Act. qty

Material consumption message

Material consumed

T-RF7##

PI_CONS

Quantity

Act. qty

Material consumption message

Material consumed

T-RF9##

PI_PHST

Signature

Signature

Message on phase status

4.

Phase end:

Interpret the result of the previous tasks. To do so, compare the process messages created so far with the input fields that you have maintained for phase 110 in the PI sheet. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

For information on process messages, refer to the pages Creating Process Messages: Scenarios 1&2 in your participant handbook. Continued on next page

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Task 11: 1.

Write down the destination types to which you can send process messages. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on message destination types, see the page Types of Message Destinations in your participant handbook.

Task 12: 1.

Which process messages are contained in the standard system and which functions do they have? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the process message categories in the standard system, see the pages Message Categories in the Standard System (I), (II) in your participant handbook.

Task 13: 1.

In the message monitor, display the characteristics for the four process messages that the system created. Write down the characteristic values. Process message category PI_PHST Message characteristics



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a)


(…) → Process Management → Message → Message Monitor Plant: 1100 Process order: Order number Enter Double-click on the message on the message monitor. Process message category PI_PHST Message characteristics


PPPI_PROCESS_ORDER

Order number

PPPI_EVENT_DATE

Date of event

PPPI_EVENT_DATE

Time of event

PPPI_PHASE

0110

PPPI_SIGNATURE

Your user

PPPI_PHASE_STATUS

Start



PPPI_PROCESS_ORDER

Order number

PPPI_EVENT_DATE

Date of event

PPPI_EVENT_DATE

Time of event

PPPI_MATERIAL

T-RF7##

PPPI_MATERIAL_CONSUMED

Material quantity withdrawn according to your entry in the PI sheet

PPPI_UNIT_OF_MEASURE

1


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PPPI_STORAGE_LOCATION

0002

PPPI_RESERVATION_ITEM

Reservation item

PPPI_RESERVATION

Reservation number



PPPI_PROCESS_ORDER

Order number

PPPI_EVENT_DATE

Date of event

PPPI_EVENT_DATE

Time of event

PPPI_MATERIAL

T-RF9##

PPPI_MATERIAL_CONSUMED

Material quantity withdrawn according to your entry in the PI sheet

PPPI_UNIT_OF_MEASURE

kg

PPPI_STORAGE_LOCATION

0002

PPPI_RESERVATION_ITEM

Reservation item

PPPI_RESERVATION

Reservation number



PPPI_PROCESS_ORDER

Order number

PPPI_EVENT_DATE

Date of event

PPPI_EVENT_DATE

Time of event

PPPI_PHASE

0110

PPPI_SIGNATURE

Your user

PPPI_PHASE_STATUS

Finish


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Task 14: 1.



2.

Write down the statuses of phase 110. _____________________________________________________ a)

Choose Operations. Double-click on the field System Status for phase 110. CRCR Control recipe created REL Released

3.

Write down the confirmed dates for phase 110. _____________________________________________________ a)

Double-click control phase number 110 on the operation overview. Choose the Dates tab page. No dates have been confirmed yet.

4.

Write down the confirmed quantities for phase 110. _____________________________________________________ a)

Choose the Qty/activities tab. No activities have been confirmed yet.

5.

Write down the quantities withdrawn for material components T-RF7## and T-RF9##. _____________________________________________________ a)

Choose Materials. Double-click the item numbers for the corresponding material components. The quantities withdrawn have not yet been updated for the two material components.


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Task 15: 1.

Send the first three messages in the message monitor (PI_PHST, PI_CONS, PI_CONS). a)

(…) → Process Management → Message → Message Monitor Plant: 1100 Process order: Order number Enter Select the first three messages (PI_PHST, PI_CONS, PI_CONS) and choose Send. After you have sent the messages, refresh the display in the message monitor. Refresh icon. The three messages must now have status Sent.

Task 16: 1.


(…) → Process order → Display Process order: Order number

2.

Write down the statuses of phase 110. _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Choose Operations. Double-click on the field System Status for phase 110. CRCR Control recipe created MCNF Manually confirmed PCNF Partially confirmed REL Release PRST Start processing Continued on next page

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3.

Write down the confirmed start date for phase 110. Compare the confirmed date and time with the characteristic values of the corresponding process message. _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Double-click control phase number 110 on the operation overview. Choose the Dates tab page. The confirmed start date (date and time) was updated for the phase. The confirmed dates are identical to the values of the message characteristics PPPI_EVENT_DATE and PPPI_EVENT_TIME for the first message of message category PI_PHST (see exercise 13).

4.

Write down the confirmed quantities for phase 110. _____________________________________________________ _____________________________________________________ a)

Choose the Qty/activities tab. No activities have been determined yet since you have only reported the phase start.

5.

Write down the quantities withdrawn for material components T-RF7## and T-RF9##. Compare the quantities with the characteristic values of the corresponding process messages. _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Choose Materials. Double-click the item numbers for the corresponding material components. The quantities withdrawn for the two materials were updated. The quantities withdrawn are identical to the values for characteristic PPPI_MATERIAL_CONSUMED for the messages of message category PI_CONS.


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Task 17: 1.

Send the fourth message in the message monitor (PI_PHST). a)

(…) → Process Management → Message → Message Monitor Plant: 1100 Process order: Order number Enter Select the fourth message (PI_PHST) and choose Send. After you have sent the message, refresh the display in the message monitor. Refresh icon. The message must now have status Sent.

Task 18: 1.



2.

Write down the statuses of phase 110. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Choose Operations. Double-click on the field System Status for phase 110. CRCR Control recipe created MCNF Manually confirmed CNF Finally confirmed PRFN Finish processing REL Released

3.

Write down the finish date for phase 110. Continued on next page

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Compare the confirmed date and time with the characteristic values of the corresponding process message. _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Double-click control phase number 110 on the operation overview. Choose the Dates tab page. The confirmed finish date (date and time) was updated for the phase. The confirmed dates are identical to the values of the message characteristics PPPI_EVENT_DATE and PPPI_EVENT_TIME for the second message of message category PI_PHST (see exercise 13).

4.

Write down the confirmed activity for phase 110. How did the system calculate this activity? _____________________________________________________ _____________________________________________________ a)

Choose the Qty/activities tab. The system used the difference between the phase finish and start dates to calculate the duration of processing.

Task 19: Alternative 2: Maintenance of process instructions in XSteps (exercises 19 to 26) 1.

Describe the principle of the maintenance of process instructions with reference to maintenance alternative 2 described in your participant handbook. To which objects are process instructions assigned in this alternative? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on process instructions, refer to the page “„Creating Control Recipes: Alternative 2” in your participant handbook.


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Task 20: 1.

How do you create control recipes in this alternative? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on control recipes, refer to the page “„Creating Control Recipes: Alternative 2” in your participant handbook.

Task 21: 1.

Go into the master recipe of the recipe group T-RCX9## in the change mode. a)

2.

Usual procedure

Can control recipe destinations be maintained for the phases? _____________________________________________________ Can process instructions be assigned to the phases? _____________________________________________________ a)

3.

Control recipe destinations cannot be maintained and process instructions cannot be assigned for the phases of the recipe.

Display the profile of the recipe. Write down the profile setting for the process instruction maintenance. Process instruction maintenance: __________________________________ What does this profile parameter define, and how does the setting selected influence the maintenance option for process instructions? Use the F1 help for the field Process instruction maintenance to answer the question. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Continued on next page

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___________________________________________________________ a)

Extras → Profile Process instruction maintenance: XSteps Use the F1 help for this profile parameter to obtain more detailed information on the possible settings and their effects.

4.

Navigate to the XStep Editor of your recipe. a)

5.

XSteps icon

Write down the following for the XStep tree: Description: _________________________________________ Application context: ___________________________________ Receiver: _________________________________________ a)

Double-click on the XStep tree Description: Fertilizer production Application context: T-RCX9## 01 Receiver: Fertilizer

6.

Write down the following information for the XSteps of the XStep tree: XStep description

Application context

Generation


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XStep description

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Application context

Generation

a)

7.

XStep description

Application context

Generation

Short text for phase

T-RCX9## 01

For all phases

Phase start with signature

T-RCX9## 01

For all phases

Control instruction with safety note

Phase 110

Work instruction

Phase 210

Work instruction

Phase 220

Material consumption

T-RCX9## 01

Goods receipt

Phase 220

Phase end with signature

T-RCX9## 01

For all phases For all phases

Which of the above XSteps were created in the recipe, and which were assigned as references to standard XSteps from the standard XStep repository? Standard XSteps: _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ XSteps created in the recipe: _____________________________________________________ _____________________________________________________


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_____________________________________________________ a)

Standard XSteps: Short text for phase Phase start with signature Material consumption of goods receipt Phase end with signature XSteps created in the recipe: Control instruction with safety note Work instruction Work instruction

8.

The process instructions for the XSteps created in the recipe are maintained in the recipe. Describe which process instruction is created with which elements for the XStep control instruction with a safety note. Description of the process instruction: _____________________________________________________ Elements of the process instruction _____________________________________________________ _____________________________________________________ a)

Expand the structure of the XStep control instruction with a safety note. A process instruction was created with the description control instruction with a safety note. Expand the structure of the process instruction. The following elements are defined for the process instruction: - Output of a long text - Output of a note text

9.

Simulate the PI sheet. Note: The explosion of the standard XStep references and the complete generation only occur in the process order. a)

XSteps → Simulate Continued on next page

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10. The process instructions for the standard XSteps are maintained in the standard XStep repository. Go into the standard XStep repository for plant 1100. a)

(...) → Production - Process → Master Data → Standard XStep Repository Plant: 1100 Execute (F8) icon

11. In the standard XStep repository, expand the folder Fertilizer production DE. You will find the standard XSteps used in your master recipe. Try to analyze the structures and contents of these standard XSteps. Use the simulation if necessary. a)


Task 22: 1.

Create a process order for material T-FF9## in plant 1100. Use process order type PO##. Enter 1000 L as the quantity you want to produce and choose today as the order start date. Manually select the production version XSDE to create the order. Immediately after the order is created, the order is released and the control recipe created. Save the order and write down the order number. ___________________________________________________________ a)

Usual procedure

Task 23: 1.


2.

Usual procedure

Display the XSteps of the process order. Note that the following activities occurred when the control recipe was created: - The standard XSteps were exploded Continued on next page

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- The generation was performed Try to analyze the structures and contents of some of these exploded and generated standard XSteps. Simulate the PI sheet. a)

Choose XSteps For the simulation: XSteps → Simulate

Task 24: 1.

Select your control recipe in the control recipe monitor and send it. a)

Usual procedure

Task 25: Call up the PI sheet that was created by sending the control recipe in the change mode. 1.

Look at the information and input fields displayed in the PI sheet. Try to find out how the XSteps of the process order are related to the various elements in the PI sheet. a)

Usual procedure

Task 26: 1.

You can now carry out the following activities corresponding to the above exercises for scenario 1: - Process the PI sheet - Analyze the process messages that the system created while you maintained the PI sheet. - Analyze in which XSteps and in which process instructions of the process order the requirements of these process messages are defined. a)

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Flexible procedure; see description in the exercise


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Lesson Summary You should now be able to: • Name the alternative maintenance options for process instructions • Describe the relationship between process instructions, control recipes, and process messages • Describe how a control recipe is created from process instructions • Describe how the information of process instructions is displayed in a PI sheet • Describe how process messages are created • Name the message destination types that are available • Name the most important predefined message categories in the standard system

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Lesson: Link to Process Control Systems

Lesson: Link to Process Control Systems Lesson Overview This lesson informs you about the principle of data exchange with process control systems using process management.

Lesson Objectives After completing this lesson, you will be able to: • • •

Describe the principle of how control recipes can be transferred to a process control system Name the process instruction types available for communicating with process control systems and explain their functions Describe typical scenarios for the data exchange between the ECC System and a process control system

Business Example You want to use the link to your process control systems with the aid of process management.

Control Recipe Transfer

Figure 116: Control Recipe Transfer

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Depending on the destination type, control recipe transfer can be triggered in the following ways: • •

As soon as at least one control recipe has been created for a destination, process management transfers all existing control recipes for this destination. Process management informs a destination about each control recipe created. Depending on the destination, individual control recipes or all existing control recipes can be requested.

From a technical point of view, communication between PP-PI and process control systems is carried out using a tRFC (transactional remote function call). The communication partners transfer data using Common Program Interface Communication (CPI-C) based on TCP/IP. Thanks to the RFC technology, the application is completely free of communication handling on the ECC level. On the control computer level, SAP supports the automatic generation of a C-coded RFC partner program with a code generator. The function module in the ECC System with which data is to be exchanged is used as the basis for the generation of the partner program. The generated program must be compiled and linked in the control computer and can then be used for the actual application as an Application Program Interface (API). The tRFC ensures that each call is executed only once. The sequence of the calls is not changed. If the target system is not active when the call takes place, the RFC is repeated according to a repetition rate or duration that can be set by the user.

Process Instruction Types for Process Control Systems

Figure 117: Process Instruction Types for Process Control Systems

You can use process parameters to transfer information to process control.

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You can use process data requests to specify that process control is to send process messages with actual process data. You specify the following: • •

The message category of the message to be sent The information to be conveyed in the message

Using process message subscriptions, you specify: • •

The events that must be reported to process management by process control The message category to be used to report an event

Example: Simple Scenario

Figure 118: Example: Simple Scenario

The graphic shows an example of how data can be transferred between PP-PI and process control in a simple process. Since the process in the sample scenario only allows for a small number of variants, it can be represented on the control side using relatively fixed algorithms, for which you can set a few parameters. In the control recipe, PP-PI transfers information on the control algorithms to be executed as well as the parameters to be used. The resources and materials are always the same and thus need not be specified. The process messages to be transferred from process control to PP-PI are not specified in the control recipe. Instead, the messages to be created and sent are defined for each control algorithm on the control side.

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Example: Complex Scenario

Figure 119: Example: Complex Scenario

The graphic shows an example of how data can be transferred between PP-PI and process control in a complex process. The process control system used in this example not only contains a number of control sequences but also resource and material data. The control sequences can be configured flexibly, thus enabling the production of a large number of variants. In the control recipe, PP-PI transfers information on the phases to be executed as well as on the resources and materials to be used. It also transfers further phase-related parameters if required. In addition to the process parameters, the control recipe contains process message subscriptions and process data requests specifying the messages that are to be sent when the control recipes are executed as well as the message characteristics. The process control system creates exactly these requested messages and sends them to PP-PI.

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Lesson Summary You should now be able to: • Describe the principle of how control recipes can be transferred to a process control system • Name the process instruction types available for communicating with process control systems and explain their functions • Describe typical scenarios for the data exchange between the ECC System and a process control system

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Lesson: Elements of PI sheets Lesson Overview This lesson informs you about important elements and functions of the PI sheet.


Name the important elements and functions of the PI sheet

Business Example You want to use PI sheets for process management and for reporting process data.

ABAP List-Based and Browser-Based PI Sheet

Figure 120: ABAP List-Based and Browser-Based PI Sheet

You can create two types of PI sheet: • •

The ABAP list-based PI sheet The browser-based PI sheet (as of Release 4.6C) This is a further development of the ABAP list-based PI sheet. Among its advantages are those of a new interface in a HTML layout and new functional options.

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Lesson: Elements of PI sheets

Since Release 4.6C, the Process Manufacturing Cockpit is also available. • •

Process Manufacturing Cockpits are PI sheets without reference to an order. They are defined in Customizing using process instructions of the type 0.

Process Instructions for PI Sheets Features • • • • • • • •

Definition of outputs (texts, fields, tables, graphics, …) Definitions of input fields and tables with default values and input validations Definition of calculations Definition of message creation Definition of function calls Definition of manufacturing data access (for example, via OPC) Definition of the phase sequence ...

Browser-Based PI Sheet - Structure

Figure 121: Browser-Based PI Sheet - Structure

This unit informs you how the browser-based PI sheet is structured in the SAP standard layout , and how its interface elements are presented.

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The browser-based PI sheet is made up of a header and the individual phases of the process order. The header and all the phases are created immediately after the PI sheet is created and they can be opened and closed. Each phase can in turn be divided into a number of sections. The appearance of a long text within a phase marks the beginning of a new section, which ends before the next long text. All the functions can be accessed via the context menu. There is also a menu bar in the header of the PI sheet that provides the functions relating to the entire PI sheet. To display the context menu, position the cursor on the relevant object or field and click the right mouse button. You can also call up the context menu with the shift + F10 key combination.

Browser-Based PI Sheet - Elements (I)

Figure 122: Browser-Based PI Sheet - Elements (I)

The phases can contain the following elements: • • •

598

Control information, notes, and input fields for long texts that are output on the left side Input and output fields and pushbuttons that appear on the right side Tables the are spread across the entire width of the PI sheet


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Browser-Based PI Sheet - Elements (II)

Figure 123: Browser-Based PI Sheet - Elements (II)

Browser-Based PI Sheet - Elements (III)

Figure 124: Browser-Based PI Sheet - Elements (III)

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Browser-Based PI Sheet - Functions (I)

Figure 125: Browser-Based PI Sheet - Functions (I)

The process operator can use a range of functions to process the browser-based PI sheet, and he can execute them for the entire PI sheet or for individual process steps. Functions that can be executed for the entire PI sheet can be triggered as follows: • •

Via the menu bar in the header of the PI sheet Via the context menu

Functions that relate to individual process steps only appear in the context menu of the respective process step if it is actually relevant to that step. For example, the function Display message only appears in those process steps for which a process message was defined. Which functions are available in the context menu also depends on whether you are displaying or changing a PI sheet.

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Browser-Based PI Sheet - Functions (II)

Figure 126: Browser-Based PI Sheet - Functions (II)

Browser-Based PI Sheet - Functions (III)

Figure 127: Browser-Based PI Sheet - Functions (III)

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Browser-Based PI Sheet - Functions (IV)

Figure 128: Browser-Based PI Sheet - Functions (IV)

When you are entering material consumptions in the PI sheet, you can also avail of the batch determination and the batch check. The batch determination and batch check are performed the same way in the PI sheet as in the order.

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Browser-Based PI Sheet - Functions (V)

Figure 129: Browser-Based PI Sheet - Functions (V)

Browser-Based PI Sheet - Functions (VI)

Figure 130: Browser-Based PI Sheet - Functions (VI)

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Signature Process for Process Steps

Figure 131: Signature Process for Process Steps

From SAP R/3 Enterprise SCM Extension 1.10 (EA_APPL 110), you can define a signature strategy for each process step, to be performed asynchronously. The last asynchronous signature in the PI sheet triggers the function Complete PI sheet. With an asynchronous signature, you have the option of only confirming actual data after one or more other people have confirmed the entries with their signature. Example: The process operator enters values during production and validates these entries with his signature. However, the system does not create any process messages yet, since the entries must be checked and signed by the shift manager at a later date. In the meantime, the process operator can process another step of the PI sheet. Only the input field that is waiting to be signed is blocked for further entries until the shift manager has signed it. If the values entered by the process operator are not permitted, the shift manager can terminate the signature process. After this, the input fields on the PI sheet will be ready for input again. New values can be entered. Only after all the required signatures in the signature strategy have been entered are the process messages relating to the process step created.

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User Change in the PI Sheet

Figure 132: User Change in the PI Sheet

From SAP R/3 Enterprise SCM Extension 1.10 (EA_APPL 110), you can change between an anonymous service user and a specific user during the processing of the PI sheet or the cockpit. A service user is a user that is available to an anonymous, larger group of users. The service user only has display rights for the PI sheet or cockpit. In the header of the PI sheet or cockpit, you will always see the name of the user currently logged on to the system. To change from the service user to a specific user, you choose Log on. To change back to the service user again, you choose Log off. An advantage: When you change between the service user and a specific user, you do not have to log off the SAP ECC System.

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Lesson Summary You should now be able to: • Name the important elements and functions of the PI sheet

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Lesson: Manufacturing Data Access

Lesson: Manufacturing Data Access Lesson Overview This lesson informs you about the principle of the Manufacturing Data Access internal interface.


Explain the principle of the Manufacturing Data Access internal interface Name the predefined services in the environment of PP-PI

Business Example You want to use the Manufacturing Data Access internal interface for manual and event-controlled reading and writing of data points.

Data Exchange Between Applications in the SAP ECC System

Figure 133: Data Exchange Between Applications in the SAP ECC System

With SAP R/3 Enterprise SCM Extension 1.10 (EA_APPL 110), the new Manufacturing Data Access internal interface was implemented. It enables you to exchange manufacturing events and data with reference to manufacturing data points between different applications in the SAP ECC System.

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You can register any application as a Service to the interface. A service can function as a client, a server, or as a client and server simultaneously. A client can • • •

Read data points from another application Write data points in another application Subscribe events from other applications

A server provides • •

Data points that can be read or written from other applications Events on which other applications can subscribe themselves

As soon as events occur, they are published by the server In this way, values from one or more data points can be • •

Read or written synchronously, on request (for example, with a pushbutton) Read or written on an event-controlled basis, which means that when applications are running, an event triggers data to be read or written automatically, without the user having to explicitly request this

Services in the Environment of PP-PI Services in the Environment of PP-PI

608

•

MDA: Generic Services

Server

•

PSH: PI Sheet

Client & Server

•

PMC: Manufacturing Cockpit

Client & Server

•

MSG: Process Messages

Client

•

ODA: OPC Data Access

Server

•

OAE: OPC Alarms/Events

Server

•

SYS: System Information

Server


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Lesson: Manufacturing Data Access

Lesson Summary You should now be able to: • Explain the principle of the Manufacturing Data Access internal interface • Name the predefined services in the environment of PP-PI

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Lesson: SAP OPC Data Access Lesson Overview This lesson informs you about the concept of SAP OPC Data Access.


Explain the basic concepts of OPC and SAP ODA.

Business Example You want to use SAP OPC Data Access to realize the exchange of data points between SAP ECC and process control systems from different manufacturers.

OPC

Figure 134: OPC

OPC stands for OLE for Process Control and Openness, Productivity and Connectivity. OPC is a standard that uses the COM/DCOM technology to define manufacturer-independent interfaces for industrial areas of application. The OPC standard was designed especially for the process control level. OPC servers enable you to access different data sources (for example, process control systems, memory programmable controls, temperature sensors) and thus provide process data which can be requested by OPC clients. SAP ECC, with the component SAP ODA, is an OPC client that can communicate with OPC servers. This considerably simplifies the data exchange between applications.

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Lesson: SAP OPC Data Access

OPC clients and OPC servers are currently PC-based systems on which a Microsoft operating system runs. You can get further information on the OPC Foundation Internet sites http://www.opcfoundation.org and www.opceurope.org.

OPC Specifications and the Scope of SAP ODA

Figure 135: OPC Specifications and the Scope of SAP ODA

SAP R/3 Enterprise SCM Extension 1.10 (EA_APPL 110) provides you with the componentSAP OPC Data Access (SAP ODA). It supports the data exchange between SAP ECC and the process control systems of different manufacturers. You can use SAP ODA to automatically write data points and events in the SAP ECC System from the process control level, or to receive them on request and write values. SAP ODA is based on the industry standard OPC (OLE for Process Control), which defines manufacturer-independent interfaces for process control technology. OPC servers provide process data that can be requested by OPC clients. SAP ECC is an OPC client that communicates with OPC servers. One part of SAP ODA is the SAP ODA Connector, which is installed on a PC outside the SAP System. To use SAP ODA, you do not have to make any additional developments or use any middleware. In contrast to the existing PI-PCS interface, for SAP ODA you do not need to have the individual process control systems certified by SAP. Therefore the installation and configuration overhead is very small.

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SAP ODA currently supports the following OPC server functions: •

OPC Data Access, which means –

•

Synchronous reading and writing of values from any and into any OPC Data Access servers – Subscribing value changes from OPC Data Access servers OPC Alarms/Events, which means –

Subscribing events from OPC Alarms/Events servers and confirming the events

The OPC functions supported by SAP ODA provide a general interface that is available for all SAP applications. This interface is currently being used in the Production Planning - Process Industry (PP-PI) area.

Example: Weighing System

Figure 136: Example: Weighing System

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SAP OPC Data Access

Figure 137: SAP OPC Data Access

The communication between the SAP ECC System, SAP ODA Connector, OPC Server, and a subordinate system works as follows: The SAP ECC System uses RFC to send, for example, a data request to the SAP ODA Connector, which acts as an RFC Server from the point of view of the SAP ECC System. The Connector converts the RFC call into an OPC-compliant call and sends it via COM to the relevant OPC Server. From the OPC point of view, it is acting as an OPC Client. The data requested is sent back the same way via COM to the Connector, and from there via RFC to the SAP ECC System. DCOM mechanisms are currently not supported by SAP ODA, and so the SAP ODA Connector and the OPC Server must be run on the same computer. However, it is possible to install any number of SAP ODA Connectors on different computers.

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SAP ODA and PI-PCS

Figure 138: SAP ODA and PI-PCS

The SAP ODA and PI-PCS interfaces provide different communication options and thus complement one another.

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Lesson Summary You should now be able to: • Explain the basic concepts of OPC and SAP ODA.

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Unit Summary

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Unit Summary You should now be able to: • Name the functions of process management • Name the alternative maintenance options for process instructions • Describe the relationship between process instructions, control recipes, and process messages • Describe how a control recipe is created from process instructions • Describe how the information of process instructions is displayed in a PI sheet • Describe how process messages are created • Name the message destination types that are available • Name the most important predefined message categories in the standard system • Describe the principle of how control recipes can be transferred to a process control system • Name the process instruction types available for communicating with process control systems and explain their functions • Describe typical scenarios for the data exchange between the ECC System and a process control system • Name the important elements and functions of the PI sheet • Explain the principle of the Manufacturing Data Access internal interface • Name the predefined services in the environment of PP-PI • Explain the basic concepts of OPC and SAP ODA.

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Test Your Knowledge

Test Your Knowledge

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1.

Name the two options in process management for exchanging data with process control systems.

2.

On the basis of which data structures are process messages requested from a PI sheet or a process control system?

3.

Name the two options for triggering the transfer of control recipes.

4.

Name a few examples from the range of functions of process instructions for PI sheets.

5.

Name services realized within the Manufacturing Data Access.

•


Server

•

PSH: PI Sheet

Client & Server

•


Client & Server

•


Client

•


Server

•


Server

•


Server


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6.

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What is the scope of OPC Data Access?


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Test Your Knowledge

Answers 1.

Name the two options in process management for exchanging data with process control systems. Answer: • •

2.

Communication with the process control level using the PI-PCS interface (sending control recipes and receiving process messages) Reading and writing data points and events using the function SAP OPC Data Access

On the basis of which data structures are process messages requested from a PI sheet or a process control system? Answer: Process messages are requested on the basis of corresponding process instructions (characteristic-based process instructions or XStep process instructions).

3.

Name the two options for triggering the transfer of control recipes. Answer: Depending on the destination type, control recipe transfer can be triggered in the following ways: •

•

4.

As soon as at least one control recipe has been created for a destination, process management transfers all existing control recipes for this destination. Process management informs a destination about each control recipe created. Depending on the destination, individual control recipes or all existing control recipes can be requested.

Name a few examples from the range of functions of process instructions for PI sheets. Answer: • • • • • • •

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Definition of outputs (texts, fields, tables, graphics, …) Definitions of input fields and tables with default values and input validations Definition of calculations Definition of message creation Definition of function calls Definition of manufacturing data access (for example, via OPC) Definition of the phase sequence


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5.

6.

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Name services realized within the Manufacturing Data Access.

•


Server

•

PSH: PI Sheet

Client & Server

•


Client & Server

•


Client

•


Server

•


Server

•


Server

What is the scope of OPC Data Access? Answer: Scope of SAP OPC Data Access (SAP ODA): In the SAP ECC System, data points and events from the process control level are received automatically or on request, and values from the ECC System are written to the process control.

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Unit 10 Process Data Evaluation Unit Overview Topics: • • • • •

Information systems: overview Order information system Process message evaluation Batch Information Cockpit Batch where-used list


Use the order information system Use process message evaluation Name important aspects of the Batch Information Cockpit Name further information systems

Unit Contents Lesson: Process Data Evaluation ............................................622 Exercise 38: Order Information System .................................629

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Unit 10: Process Data Evaluation

SCM340

Lesson: Process Data Evaluation Lesson Overview This lesson provides you with an overview of the different information systems for process data evaluation.


Use the order information system Use process message evaluation Name important aspects of the Batch Information Cockpit Name further information systems

Business Example You will test the functions of the order information system. You will get an overview of the functions of process message evaluation. You will get an overview of the options for evaluating batch data using the Batch Information Cockpit. You will get an overview of further information systems.

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Lesson: Process Data Evaluation

Information Systems

Figure 139: Information Systems

Order Information System

Figure 140: Order Information System

The order information system is a tool that offers the following shop floor control reporting functions for process orders: All orders that exist in the system can be included in the evaluations (including those with deletion flags/indicators). Archived orders are not taken into account. The order information system offers various list types in reporting. Their layout can be tailored to your requirements.

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Process Message Evaluation

Figure 141: Process Message Evaluation

You can use process message evaluation to evaluate characteristics of process messages that have been sent to the process message record. You can display characteristic values in the SAP Business Graphics. You can transfer evaluation results to MS-EXCEL, download them to your PC in ASCII format, or send them to the SAPoffice mail system.

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Batch Information Cockpit

Figure 142: Batch Information Cockpit

The Batch Information Cockpit is a central tool that provides comprehensive evaluation options for batch data. It was developed within the scope of the Enjoy release as a one-screen transaction. In the Batch Information Cockpit you can start a flexible selection of batch data. You can enter a range of basic data in the selection screen: for example, material, stock, or shelf life data, or specification data that is stored in the classification. Existing batch functions have also been integrated: • • •

Batch master and batch where-used list Stock overview and minimum shelf life evaluations Worklist

The BIC is a new development for Release 4.6C (downgrade available for 4.6B). You can start it with transaction /nBMBC.

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Structure of the Batch Where-Used List

Figure 143: Structure of the Batch Where-Used List

The batch where-used list documents a batch's path through the enterprise. The batch where-used list is used within the scope of product liability. This report enables you to find batches which, for example, must be recalled for quality reasons. You use top-down analysis to determine which batches a batch came from, and bottom-up analysis to determine which batches a batch went into. The batch where-used list is structured on the basis of material movement data for materials subject to batch management. It also considers transfers from charge to charge, stock transfers in the two-step procedure, and purchase orders (including subcontracting orders). You can start the batch where-used list from the batch management menu or from the Batch Information Cockpit. If you want to use the batch where-used list, for example, to evaluate information from the sales or warehouse management areas, you can either use the pick-up list in the batch management menu or the batch related objects selection expansion in the Batch Information Cockpit. From the pick-up list, you access the batch where-used list by means of various SD documents. Display options: • •

626

Tree structure: hierarchical structure ALV list: Additional fields can be added to the list by means of the SAP enhancement SAPLCHVW.


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Process Data Evaluation: Topic Summary • • • •

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The order information system is a tool that offers reporting and mass processing functions for process orders. You can use process message evaluation to evaluate characteristics of process messages. The Batch Information Cockpit provides comprehensive evaluation options for batch data. The batch where-used list documents a batch's path through the enterprise. It is is used within the scope of product liability.


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Exercise 38: Order Information System Exercise Objectives After completing this exercise, you will be able to: • Use the process order information system

Business Example You will become familiar with the process order information system.

Task 1: 1.

1. Go into the process order information system.

2.

Which list types are available?

Task 2: 1.

Select the list PPIOA000 Object overview and the profile 00000000001X Standard profile layout-based. In the selection tab page, for example, choose the selection options production plant 1100 and order type PO##. Get an overview of all the selection options available. In the object selection tab page, check the object selection proposed by the profile. Finally, execute the program (Program → Execute (F8)).

2.

After executing the program, analyze the generated lists: In the left chart (= object list), the Objects column contains a list of all the process orders read for the current evaluation. You can expand the orders hierarchically in a tree structure relating to the objects selected in the object selection. To the right of the object list, you get a special individual object list with field information for every object selected in the object selection. If you want to restrict the information displayed in the individual lists to particular objects in the object list, you can double-click on the object or use the Restrict individual lists function.


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The field selection in the object list and in the individual lists can be personalized by means of layout definitions. To do this in the individual lists, you switch on the standard list functions using the corresponding function button. Individual lists can be switched to full-screen mode. You can open and close them using Settings → Individual list selection. From the individual lists, you can use the environment function selection to navigate in detailed information.

Task 3: 1.

Analyze the information of detailed lists (for example, PPIOH000 order headers, PPIOR000 confirmations, …) in the process order information system. Note that you can select a profile or a layout in the initial screen to preset the field selection for detailed lists.

Task 4: 1.

630

Display the profiles defined in Customizing for the order information system.


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Solution 38: Order Information System Task 1: 1.

1. Go into the process order information system. a)

2.

Logistics → Production - Process → Process Order → Reporting → Order Information System → Process Order Information System

Which list types are available? a) PPIOD000

Documented goods movements

PPIOG000

Automatic goods movements

PPIOH000

Order headers

PPIOI000

Items

PPIOK000

Capacities

PPIOO000

Operations

(…)

Task 2: 1.

Select the list PPIOA000 Object overview and the profile 00000000001X Standard profile layout-based. In the selection tab page, for example, choose the selection options production plant 1100 and order type PO##. Get an overview of all the selection options available. In the object selection tab page, check the object selection proposed by the profile. Finally, execute the program (Program → Execute (F8)). a)

2.


After executing the program, analyze the generated lists: In the left chart (= object list), the Objects column contains a list of all the process orders read for the current evaluation. You can expand the orders hierarchically in a tree structure relating to the objects selected in the object selection. Continued on next page

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To the right of the object list, you get a special individual object list with field information for every object selected in the object selection. If you want to restrict the information displayed in the individual lists to particular objects in the object list, you can double-click on the object or use the Restrict individual lists function. The field selection in the object list and in the individual lists can be personalized by means of layout definitions. To do this in the individual lists, you switch on the standard list functions using the corresponding function button. Individual lists can be switched to full-screen mode. You can open and close them using Settings → Individual list selection. From the individual lists, you can use the environment function selection to navigate in detailed information. a)


Task 3: 1.

Analyze the information of detailed lists (for example, PPIOH000 order headers, PPIOR000 confirmations, …) in the process order information system. Note that you can select a profile or a layout in the initial screen to preset the field selection for detailed lists. a)

Task 4: 1.

Display the profiles defined in Customizing for the order information system. a)

632

Customizing: (…) → Process Order → Information System → Define Profiles for Order Information System


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Lesson Summary You should now be able to: • Use the order information system • Use process message evaluation • Name important aspects of the Batch Information Cockpit • Name further information systems

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Unit Summary

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Unit Summary You should now be able to: • Use the order information system • Use process message evaluation • Name important aspects of the Batch Information Cockpit • Name further information systems

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Test Your Knowledge

Test Your Knowledge 1.

2005/Q2

Name the information systems for process data evaluation


635

Test Your Knowledge

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Answers 1.

Name the information systems for process data evaluation Answer: • • • • • • •

636

Order Information System Process Message Evaluation Missing Parts Information System Business Information Warehouse Logistics Information System LIS Batch Information Cockpit; also with Batch Where-Used List Controlling Reports


2005/Q2

Unit 11 Production in Compliance with GMP Unit Overview Topics: • • • • • •

Digital signature Approved process orders Material identification and material reconciliation Integration with quality management Batch record Batch derivation

Unit Objectives After completing this unit, you will be able to: • • • • • • • • • • • • • • •

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Name the functions for realizing production in compliance with GMP Give a definition for digital signatures and describe their functions and processing Name the applications using digital signatures in the ECC System Execute a digital signature Find and display digital signatures Define a signature strategy and describe how it is applied Create approved process orders Change approved process orders Use the picking function to pack material components into handling units Carry out a completeness check to identify the material components staged Perform quantity reconciliation for the materials involved in the process Outline the main steps that must be followed in master data maintenance to carry out an in-process quality inspection Describe the functions of inspection lots and create an inspection lot for in-process quality inspection Describe possible scenarios of an in-process quality inspection Carry out in-process quality inspections with batch value assignment


637

Unit 11: Production in Compliance with GMP

• • • •

•

SCM340

Describe the structure and process of editing a batch record Explain the status profile and version management for batch records Explain how you can influence batch status management and the usage decision for an inspection lot Describe how you can use batch derivation to transfer values from batch attributes in the batch where-used list for component batches to batches of a finished product Name the settings required in Customizing and in the application

Unit Contents Lesson: Production in Compliance with GMP - Overview .................639 Lesson: Digital Signature ......................................................642 Exercise 39: Digital Signature: Definition and Application ............657 Exercise 40: Individual Signatures and Signature Strategies ........661 Lesson: Approved Process Orders ...........................................677 Exercise 41: Approved Process Orders .................................681 Lesson: Material Identification and Material Reconciliation ...............692 Exercise 42: Material Identification.......................................699 Lesson: Integration with Quality Management ..............................707 Exercise 43: Integration with Quality Management ....................715 Exercise 44: Material Reconciliation .....................................727 Lesson: Batch Record..........................................................732 Exercise 45: Batch Record................................................739 Lesson: Batch Derivation ......................................................748

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Lesson: Production in Compliance with GMP - Overview

Lesson: Production in Compliance with GMP - Overview Lesson Overview This lesson provides you with an overview of functions for realizing production in compliance with GMP.


Name the functions for realizing production in compliance with GMP

Business Example The guidelines on Good Manufacturing Practices (GMP) laid down by the U.S. Food and Drug Administration (FDA) and other international institutions have become an international standard in many areas of process industries. In particular, they must be taken into account in processes of the pharmaceutical industry.

Production in Compliance with GMP

Figure 144: Production in Compliance with GMP

The guidelines on Good Manufacturing Practices (GMP) laid down by the U.S. Food and Drug Administration (FDA) and other international institutions have become an international standard in many areas of process industries. In particular, they must be taken into account in processes of the pharmaceutical industry.

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You can specify that a process order can only be created if an approved recipe exists. The order data is therefore locked and cannot be changed. The approval procedure is implemented in the ECC Engineering Change Management. You use the material identification function to check whether the material that was picked for the process order is completely available at the production line and will be used in the correct sequence. You can exchange information about the product quality and analysis values between the production plant and the laboratory or the quality assurance system. You use ECC Quality Management to do this.You can use the inspection results for batch specification by automatically copying them to the characteristics of the batch produced. You use the material reconciliation function to analyze and verify required quantities and yield at the end of the production process. With regard to product liability, the batch record contains all planned and actual data for the production process of a batch. You can activate the digital signature function to execute certain business operations in the ECC System.

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Lesson: Production in Compliance with GMP - Overview

Lesson Summary You should now be able to: • Name the functions for realizing production in compliance with GMP

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Lesson: Digital Signature Lesson Overview This lesson informs you about realizing the digital signature.

Lesson Objectives After completing this lesson, you will be able to: • • • • •

Give a definition for digital signatures and describe their functions and processing Name the applications using digital signatures in the ECC System Execute a digital signature Find and display digital signatures Define a signature strategy and describe how it is applied

Business Example You are a member of the project team implementing the SAP System in a pharmaceutical company. You must ensure that certain business transactions in process manufacturing may only be carried out if special approvals and identification procedures are followed. In addition, these transactions must be documented. You will therefore get an overview of the functions and applications of the Digital Signature in the ECC System. You will test this function when maintaining a PI sheet.

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Lesson: Digital Signature

Digital Signature: Definition (I)

Figure 145: Digital Signature: Definition (I)

The digital signature has the same function for processing digital data as the hand-written signature has for paper documents.

Digital Signature: Definition (II)

Figure 146: Digital Signature: Definition (II)

You can specify that a user must execute a digital signature to be able to carry out particular business transactions in the ECC System.

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The digital signature enables you to meet the security requirements laid down in the guidelines on Good Manufacturing Practices (GMP) with regard to the execution of these transactions. The digital signature ensures that: • •

•

A transaction can only be carried out by users with a special authorization The user identification is unique and forgery-proof. Depending on the signature method, the ECC user name and ECC password can be used to sign, or an external security software for signature identification (for example, using a card reader) can be connected via an interface The name of the user is documented together with the signed transaction and the date and time, and cannot be manipulated afterwards

Depending on the application, the user can or must also enter a comment on the digital signature If a transaction must be signed by several users, you can combine individual signatures of different user groups into application-specific signature strategies

Signature Methods

Figure 147: Signature Methods

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Linking External Security Products

Figure 148: Linking External Security Products

The Secure Store and Forwards (SSF) interface is used to realize digital signatures for the signature method User Signature with External Security Product in the ECC System. SSF allows you to link several external security products with different identification procedures. By doing this, digital signatures can be used as independent units for the protection of data and documents if they are saved to data mediums or are transferred via communication links. The system supports, for example, the identification and signature execution using chip cards and files. The user-specific data (such as the password and private key) is stored on the smart card or encoded on the file. After the users identify themselves, document data is transferred to the security product. The digital signature is created on the basis of this data and is returned to the ECC System.

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Processing of Digital Signatures (I)

Figure 149: Processing of Digital Signatures (I)

Applying Digital Signatures

Figure 150: Applying Digital Signatures

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At present, the digital signature is implemented for the following transactions: •

Quality Management (QM) area:

•

– Saving inspection results for an inspection lot – Recording and changing the usage decision for an inspection lot – Releasing a physical sample drawing Engineering Change Management (ECH) area – –

Changing the status of an engineering change request/order Changing the status of a change object of an engineering change request/order The approval procedures for recipes and inspection plans are, for example, based on the execution of engineering change requests/orders.

•

Production Planning for Process Industries (PP-PI) area

•

– Completing a process step in the PI sheet – Accepting invalid values during input validations in the PI sheet – Approving a batch record Document Management area –

Set document status

Activating the “Digital Signature” Function

Figure 151: Activating the “Digital Signature” Function

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Digital Signature: Example

Figure 152: Digital Signature: Example

Signature Strategies

Figure 153: Signature Strategies

Depending on the application and the setting, a signature consists of just one signature

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Dual control, or a number of individual signatures stored in a signature strategy. A signature strategy specifies: • • •

Which individual signatures are required, this means, which user groups must sign the operation In which sequence the individual signatures must be executed Which signature or signatures can complete the signature process

A user may execute a maximum of one signature within a signature strategy. Digital signatures and their application: • • • •

PI Sheet: digital signatures with and without signature strategies Batch record: digital signatures with and without signature strategies Engineering change request/order: digital signatures only with signature strategies Quality management: signature strategies for digital signatures are not supported

Signature Strategy: Authorization Groups

Figure 154: Signature Strategy: Authorization Groups

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You can use authorization groups to restrict the authorization to execute digital signatures as follows: • •

•

For users with different areas of responsibility, you define different authorization groups. In the user master record, you assign each user the authorization for the authorization group corresponding to his or her area of responsibility (authorization object C_SIGN_BGR). You define individual signatures that must be entered by users of a certain authorization group and use them in the signature strategies for a business transaction.

The authorization groups are not taken into account if a transaction is signed by an individual signature without a signature strategy.

Signature Strategy: Individual Signatures

Figure 155: Signature Strategy: Individual Signatures

An individual signature is a digital signature that must be executed by a certain user group. Individual signatures of different user groups are combined in signature strategies that are carried out when a transaction is signed. An individual signature is a partial step in a signature process. If you only want to use one signature without a signature strategy to sign a transaction, you do not need to define individual signatures.

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Defining Signature Strategies

Figure 156: Defining Signature Strategies

To create a new signature strategy, proceed as follows: • • • •

Enter a key and a description for the signature strategy. Assign the individual signatures to be used. Specify the sequence of the individual signatures. Define the release statuses, which specify which signature or signatures can complete the signature process.

Signature Strategy: Assign Individual Signatures

Figure 157: Signature Strategy: Assign Individual Signatures

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You assign the individual signatures that must or can be executed when carrying out a signature strategy. You can assign the same individual signature several times or assign several different individual signatures with the same authorization group. When executing the signature strategy, each user of the authorization group may only execute one signature.

Signature Strategy: Define Signature Sequence

Figure 158: Signature Strategy: Define Signature Sequence

You determine the sequence in which the individual signatures of a signature strategy must be executed. You specify the signature sequence by selecting the predecessors for each individual signature in a sequence matrix.

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Signature Strategy: Define Release Statuses

Figure 159: Signature Strategy: Define Release Statuses

You define one or more alternative release statuses for a signature strategy. For each release status, you also specify a combination of individual signatures with which the signature process can be completed. A signature process is not complete until all signatures for a release status have been executed. If you do not define a release status for a signature strategy, all individual signatures of the signature strategy must be executed in every signature process. You define a release status by selecting the required signature combination in the overview of the possible signature combinations.

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Signature Strategy: Example

Figure 160: Signature Strategy: Example

Displaying and Finding Digital Signatures

Figure 161: Displaying and Finding Digital Signatures

You can display a signature executed for an inspection lot, engineering change order, PI sheet, or a batch record from the object itself.

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For reporting purposes, you can search for digital signatures based on a number of different criteria, such as: • • •

Signatory Creation date and time Object type for which the signature was executed (for example, engineering change order or inspection lot)

You obtain a list of the objects for which digital signatures have been executed. You can navigate to the objects from the list and display all of the signatures for them.

Digital Signature: Topic Summary • •

•

• •

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You can specify that a user must execute a digital signature to be able to carry out particular business transactions in the ECC System. The digital signature ensures that a user is uniquely identified and that the user name is documented together with the signed transaction, date, and time, and cannot be forged. You can choose between the signature methods System signature with authorization by ECC user ID and ECC password and User signature with external security product. The SSF interface enables the linking of various external security products supporting different identification procedures. You can define signature strategies containing individual signatures of different user groups.


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Exercise 39: Digital Signature: Definition and Application Exercise Objectives After completing this exercise, you will be able to: • Describe the definition and function of digital signatures • Describe the linking of external security products • Describe the processing of digital signatures • Name the applications using digital signatures in the ECC System

Business Example You will get an overview of the topic “Digital Signatures”.

Task 1: 1.

Give a definition and describe the function of digital signatures. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: 1.

Describe how the digital signature is linked to external security products and how it is processed. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Continued on next page

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___________________________________________________________ ___________________________________________________________

Task 3: 1.

In which applications can the digital signature be used at the moment? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

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Solution 39: Digital Signature: Definition and Application Task 1: 1.

Give a definition and describe the function of digital signatures. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

To answer this question, see the pages Digital Signature: (I), (II) in your participant handbook.

Task 2: 1.

Describe how the digital signature is linked to external security products and how it is processed. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For more information about the process of digital signature execution, refer to the pages Linking External Security Products and Processing Digital Signatures in your training manual.


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Task 3: 1.

In which applications can the digital signature be used at the moment? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

660

To answer this question, see the pages Applications Using Digital Signatures and Activating the Digital Signature Function in your participant handbook.


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Exercise 40: Individual Signatures and Signature Strategies Exercise Objectives After completing this exercise, you will be able to: • Activate the Digital Signature function for a control recipe destination • Execute and display a digital signature in the PI sheet • Define a signature strategy in Customizing • Process a signature strategy in the PI sheet • Search for digital signatures

Business Example You will activate the Digital Signature function for a control recipe destination. You will maintain a PI sheet for this control recipe destination and execute a digital signature. You will display the signature in the PI sheet. You will define a signature strategy for the control recipe destination. You will become familiar with signature strategy details. You will work with the signature strategy in the PI sheet and display the signatures you execute.

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Task 1: Note: For the following exercises, the control recipe destinations are assigned to the participant groups as follows: Control recipe destination

For groups

C0 to C9

00 to 09

D0 to D9

10 to 19

E0 to E9

20 to 29

F0

30

Description of the control recipe destination: Operator Group ##/A Destination address: GRP. ##/A CERM 1.

In Customizing, display the detail data of your control recipe destination Operator Group ##/A (destination address GRP. ##/A CERM) for plant 1100. Check whether the Digital Signature indicator has been set.

Task 2: 1.

Display the signature methods set up in Customizing. Make sure that the signature method System signature with authorization by SAP R/3 user ID/password is defined for the signing of process steps in the PI sheet and the accepting of invalid values in the PI sheet.

Task 3: 1.

Create a process order of order type PO## for material T-CERM-## in plant 1100. Choose 1000 kg as an order quantity and today’s date as the start date. Release the order, generate the control recipes, and, in the control recipe monitor, send the control recipe to control recipe destination address GRP. ##/A CERM.


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Task 4: Find and maintain your PI sheet for the control recipe destination above. Hint: You maintain an ABAP list-based PI sheet in this scenario. 1.

Confirm the start of phase 11 by entering your Digital Signature. Sign with your user name and confirm with your SAP ECC password.

2.

Display the digital signature in the PI sheet.

3.

Finish processing phase 11. Do not process phase 12 yet. Save and exit the PI sheet.

Task 5: 1.

In Customizing, make the following changes in the detail data of your control recipe destination Operator Group ##/A of plant 1100: Enter the following: Signature strategy for deviations: PI_VALID Do not define a signature strategy for process steps.

Task 6: 1.

Describe the function of signature strategies. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________


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Task 7: Familiarize yourself with the Customizing settings for the selected signature strategy before further maintaining the PI sheet. 1.

Call up the Customizing activity Define Signature Strategy. Display individual signatures defined for strategy PI_VALID. Write down the following: Indiv.sig.

2.

Indiv. signature description

AGrpDigSig

Display the signature sequences defined for strategy PI_VALID. Write down the following: Signatures to be executed

Predecessor signatures SIGN_A

SIGN_S

SIGN_Q

SIGN_P

SIGN_A SIGN_S SIGN_Q SIGN_P Try to draw a graphic of the signature sequence.


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3.

Display the release statuses defined for strategy PI_VALID. Write down the following: Release statuses

Indiv. signatures required for release SIGN_A

SIGN_S

SIGN_Q

SIGN_P

Try to draw a graphic of the release statuses.

Task 8: Continue maintaining your PI sheet for control recipe destination Operator Group ##/A. 1.

Confirm the start of phase 12 by entering your Digital Signature. Sign with your user name and confirm with your SAP ECC password. Did you have to follow a signature strategy to confirm the start of the phase? ______________________________________________________ Why not? ______________________________________________________

2.

In the next step, enter a pH value of 4.7.


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Pay attention to the result of the input validation. The value you entered is outside of the tolerance defined in planning. In the production process, it was not possible to change this value. You must therefore accept it. To actually accept this value, several different people of different authorization groups must execute individual signatures according to a signature strategy. Which signature strategy is to be followed? Why? _____________________________________________________ _____________________________________________________ _____________________________________________________ Use the following user names to execute the individual signatures defined in the strategy: Indiv. signature

Signatory

SIGN_A

MILLER_A

SIGN_S

SMITH_S

SIGN_Q

JONES_Q

SIGN_P

KING_P

Enter a comment for each individual signature. Confirm the individual signatures with the password SONNE. Execute the individual signatures until a release status has been reached. 3.

In the PI sheet, display the digital signatures you executed above with regard to the strategy type PI_VALID. Display the comment for a signature.

4.

Save and exit the PI sheet.

Task 9: 1.

Search for the digital signatures you have executed so far in your PI sheet via the corresponding evaluation function in process management. Choose reasonable selection criteria, such as the number of your PI sheet. Display all the signatures executed for the PI sheet.

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Solution 40: Individual Signatures and Signature Strategies Task 1: Note: For the following exercises, the control recipe destinations are assigned to the participant groups as follows: Control recipe destination

For groups

C0 to C9

00 to 09

D0 to D9

10 to 19

E0 to E9

20 to 29

F0

30

Description of the control recipe destination: Operator Group ##/A Destination address: GRP. ##/A CERM 1.

In Customizing, display the detail data of your control recipe destination Operator Group ##/A (destination address GRP. ##/A CERM) for plant 1100. Check whether the Digital Signature indicator has been set. a)

Customizing: Production Planning for Process Industries → Process Management → Control Recipes/PI Sheets → Control Recipe Destinations → Define and Set Up Control Recipe Destinations Plant: 1100 Double-click on the line of your control recipe destination Operator Group ##/A. The Digital Signature indicator is set.

Task 2: 1.

Display the signature methods set up in Customizing.


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Make sure that the signature method System signature with authorization by SAP R/3 user ID/password is defined for the signing of process steps in the PI sheet and the accepting of invalid values in the PI sheet. a)

Customizing: Production Planning for Process Industries → Process Management → Control Recipes / PI Sheets → Digital Signatures → Specify Signature Method for Approval Using Simple Signature The signature method System signature with authorization by R/3 user ID/password is defined for the signing of process steps in the PI sheet and the accepting of invalid values in the PI sheet.

Task 3: 1.

Create a process order of order type PO## for material T-CERM-## in plant 1100. Choose 1000 kg as an order quantity and today’s date as the start date. Release the order, generate the control recipes, and, in the control recipe monitor, send the control recipe to control recipe destination address GRP. ##/A CERM. a)

(See description in exercise, no further details required)

Task 4: Find and maintain your PI sheet for the control recipe destination above. Hint: You maintain an ABAP list-based PI sheet in this scenario. 1.

Confirm the start of phase 11 by entering your Digital Signature. Sign with your user name and confirm with your SAP ECC password. a)

2.

Display the digital signature in the PI sheet. a)

3.

No further details required Position your cursor on your signature in the PI sheet and choose Signature.

Finish processing phase 11. Do not process phase 12 yet. Save and exit the PI sheet. a)

No further details required Continued on next page

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Task 5: 1.

In Customizing, make the following changes in the detail data of your control recipe destination Operator Group ##/A of plant 1100: Enter the following: Signature strategy for deviations: PI_VALID Do not define a signature strategy for process steps. a)

Customizing: (…) → Define and Set Up Control Recipe Destination Plant: 1100 Double-click on the line of your control recipe destination Operator Group ##/A. Signature strategy for deviations: PI_VALID Save the changes for your control recipe destination.

Task 6: 1.

Describe the function of signature strategies. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

For information on the function of signature strategies, see the page Signature Strategies in your participant handbook.

Task 7: Familiarize yourself with the Customizing settings for the selected signature strategy before further maintaining the PI sheet. 1.

Call up the Customizing activity Define Signature Strategy. Display individual signatures defined for strategy PI_VALID. Continued on next page

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Write down the following: Indiv.sig.

a)


AGrpDigSig

Customizing: (...) → Process Management → Control Recipes/PI Sheets → Digital Signatures → Signature Strategy → Define Signature Strategies On the overview screen for signature strategies, choose the line for strategy PI_VALID and in the dialog structure, choose → Assign individual signatures.

2.

Indiv.sig.


AGrpDigSig

SIGN_A

Process operator approval

PIA

SIGN_S

Shift manager approval PIS

SIGN_Q

Quality manager approval

PIQ

SIGN_P

Production director approval

PIP

Display the signature sequences defined for strategy PI_VALID. Write down the following: Signatures to be executed


SIGN_S

SIGN_Q

SIGN_P

SIGN_A SIGN_S SIGN_Q SIGN_P


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Try to draw a graphic of the signature sequence.

a)

On the overview screen for signature strategies, choose the line for strategy PI_VALID and choose Signatures. Signatures to be executed


SIGN_S

SIGN_Q

SIGN_P

SIGN_A SIGN_S

X

SIGN_Q

X

SIGN_P

X

X

A display of this signature sequence in graphical form can be found on the Signature Strategy: Define Signature Sequence page in your participant handbook. 3.

Display the release statuses defined for strategy PI_VALID. Write down the following: Release statuses


SIGN_S

SIGN_Q

SIGN_P


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Try to draw a graphic of the release statuses.

a)

On the overview screen for signature strategies, choose the line for strategy PI_VALID and choose Release. Release statuses


SIGN_S

SIGN_Q

SIGN_P

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

A display of these release statuses in graphical form can be found on the Signature Strategy: Define Release Statuses page in your participant handbook.

Task 8: Continue maintaining your PI sheet for control recipe destination Operator Group ##/A. 1.

Confirm the start of phase 12 by entering your Digital Signature. Sign with your user name and confirm with your SAP ECC password. Did you have to follow a signature strategy to confirm the start of the phase? ______________________________________________________ Why not? Continued on next page

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______________________________________________________ a)

In this case, no signature strategy must be followed. In the detail data for your control recipe destination, no strategy is defined in the field Signature strategy for process steps (compare exercise 5).

2.

In the next step, enter a pH value of 4.7. Pay attention to the result of the input validation. The value you entered is outside of the tolerance defined in planning. In the production process, it was not possible to change this value. You must therefore accept it. To actually accept this value, several different people of different authorization groups must execute individual signatures according to a signature strategy. Which signature strategy is to be followed? Why? _____________________________________________________ _____________________________________________________ _____________________________________________________ Use the following user names to execute the individual signatures defined in the strategy: Indiv. signature

Signatory

SIGN_A

MILLER_A

SIGN_S

SMITH_S

SIGN_Q

JONES_Q

SIGN_P

KING_P

Enter a comment for each individual signature. Confirm the individual signatures with the password SONNE.


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Execute the individual signatures until a release status has been reached. a)

pH value: 4.7 The PI Sheet: Maintain dialog box appears. Here the result of the input validation containing errors is displayed. Choose Copy. The Digital Signature: Executing A Signature Strategy dialog box appears. Signature strategy PI_VALID must be followed. In the detail data for your control recipe destination, you defined the strategy PI_VALID in the field Signature strategy for deviations (compare exercise 5). Execute the individual signatures as described in the exercise. You exit the Digital Signature: Executing A Signature Strategy dialog box when a release status is reached.

3.

In the PI sheet, display the digital signatures you executed above with regard to the strategy type PI_VALID. Display the comment for a signature. a)

Position your cursor on the pH value containing errors in the PI sheet and choose Signature. To display the comment for a signature, position the cursor on the relevant line and choose Display comment.

4.

Save and exit the PI sheet. a)

No instruction required

Task 9: 1.

Search for the digital signatures you have executed so far in your PI sheet via the corresponding evaluation function in process management. Choose reasonable selection criteria, such as the number of your PI sheet.


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Display all the signatures executed for the PI sheet. a)

Logistics → Production - Process → Process Management → Evaluations → Find Digital Signatures The Find Digital Signatures screen appears. In the PI sheet group box, enter, for example, the number of your PI sheet as the selection criteria (or choose other reasonable selection criteria). Choose Execute (F8). Position your cursor on the number of the PI sheet and choose All signatures.

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Lesson Summary You should now be able to: • Give a definition for digital signatures and describe their functions and processing • Name the applications using digital signatures in the ECC System • Execute a digital signature • Find and display digital signatures • Define a signature strategy and describe how it is applied

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Lesson: Approved Process Orders

Lesson: Approved Process Orders Lesson Overview This lesson informs you about approved process orders.


Create approved process orders Change approved process orders

Business Example You are a member of the project team implementing the SAP System in a pharmaceutical company. You must make sure that certain production procedures are only carried out based on approved recipes and approved process orders. You will create approved process orders and test a user-defined approval procedure to change these orders.

Recipe Approval (I)

Figure 162: Recipe Approval (I)

You can specify that a detailed, company-specific approval procedure must be followed when creating and changing master recipes.

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Once the procedure has been released, the edited recipe is marked as Approved recipe.

Recipe Approval (II)

Figure 163: Recipe Approval (II)

The engineering change orders of ECC Engineering Management are the basis for the approval procedure. The change process using an engineering change request comprises three main steps: Creating an engineering change request Checking an engineering change request and converting it into an engineering change order Changing objects and completing the change For a master recipe marked with change type "With engineering change order", this process represents an approval procedure. Once the procedure has been released, the maintained recipe is marked as Approved recipe for the change period defined by the valid-from date of the change request. Recipes that have already been approved but are changed using another change order are considered as unapproved during the period between the conversion and release for the change period defined by the valid-from date. The approval procedure was also implemented for inspection plans. You can define that a digital signature is required for particular process steps, such as to convert a change request into a change order and release a change order.

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Approved Process Orders

Figure 164: Approved Process Orders

You can specify that the process orders of a specific order type must have been approved before they can be released. Process orders can be approved in either of the following ways: By selecting an approved recipe when creating the process order, or By approving the process order individually after it has been created Only MRP data can be changed for an approved process order. You can specify that specific authorizations are required to change other order data. The above functions are implemented in ECC process order management and ECC status management.

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Changing Approved Process Orders: Example

Figure 165: Changing Approved Process Orders: Example

You can use the Withdraw approval function in the process order to reset the system statuses APG and APRC. The system status APNG Approval not granted is set again. This means that all process order data may now be changed again. To reset the APNG status, you must carry out the Individual approval function in the process order. The order is then reassigned the APG status and the status APGS Single approval granted. The order data is now again locked against changes. You can specify that a special authorization is required to carry out the Withdraw approval and Individual approval functions. You can do so by prohibiting or permitting these transactions for certain user statuses.

Approved Process Orders: Topic Summary • •

• •

680

You can specify that process orders of a specific order type have to be approved. A process order can be approved by selecting an approved recipe when creating the process order or by approving the order individually after it has been created. Only MRP data can be changed for an approved process order. You can use a user status profile to define the change procedure for approved process orders.


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Exercise 41: Approved Process Orders Exercise Objectives After completing this exercise, you will be able to: • Make Customizing settings for order approval • Describe an approved recipe • Create an approved order on the basis of an approved recipe • Withdraw order approval • Perform individual order approval

Business Example In Customizing, you will define that process orders must be approved for your order type-dependent parameters. You create a process order based on an approved recipe whereby the order itself is approved. You will test the functions of withdrawing order approval and individual approval. You will use a user status profile to represent an approval procedure in the order.

Task 1: 1.

Display the order type-dependent parameters for plant 1100 and order type PO## in Customizing.

2.

On the Master data tab, set the Approval required and Batch record required indicators. Which functions do these indicators have? If required use the field help (F1) to answer this question. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ Save your settings. Continued on next page

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Task 2: 1.

Assign user status profile PI_APPR, Approved process orders to your order type PO## in Customizing. Note: The user status profile determines that you can only withdraw and grant process order approval by setting the corresponding user status. Note that you can define a specific authorization that is required to set a user status.

Task 3: 1.

Try to make changes in master recipe T-TAB## (for example, changes to a phase).

2.

Which message does the system issue? _____________________________________________________ _____________________________________________________ _____________________________________________________

3.

What do you need to do to make changes to the recipe? _____________________________________________________ _____________________________________________________ _____________________________________________________

4.

With reference to which change order has the recipe been approved? Display the administrative data of the recipe to answer this question. Change number: ___________________________________________

5.

The recipe describes the production of which material? ______________________________________________________

Task 4: 1.

Create a process order of order type PO## for material T-HTB2## in plant 1100. Enter 100 000 PC as the order quantity.

2.

Which recipe did the system select for order creation? _____________________________________________________ Continued on next page

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3.

Which system and user statuses were set with regard to order approval when you created the order? _____________________________________________________ _____________________________________________________ _____________________________________________________

4.

Try to change data other than MRP data (for example, make changes to the data of a phase). What do you notice? ______________________________________________________

5.

Try to withdraw the order approval. Which message does the system issue? ______________________________________________________ Display the status information for the message. Why can you not withdraw the approval at present? ______________________________________________________

6.

Set the user status WDAL Withdr. allowed/no indiv.approv.

7.

Withdraw the order approval. Which new system status is set? ____________________________________________________ _____________________________________________________ Can you now change data other than MRP data? ______________________________________________________

8.

Try to release the order. Which message does the system issue? ______________________________________________________ Display the status information for the message. Why can you not release the order at the moment? ______________________________________________________

9.

Try to manually approve the order in individual processing. Which message does the system issue? _____________________________________________________


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Display the status information for the message. Why can you not approve the order individually at the moment? _____________________________________________________ 10. Set the user status IAAL Individual approval allowed. 11. Individually approve the order. Which new system and user statuses were set after the individual approval? _____________________________________________________ _____________________________________________________ _____________________________________________________ Can you still change data other than MRP data? ______________________________________________________ Finally, save your order and write down the order number. ______________________________________________________ 12. Display your order once again. Display all change documents for the status changes.

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Solution 41: Approved Process Orders Task 1: 1.

Display the order type-dependent parameters for plant 1100 and order type PO## in Customizing. a)

Customizing: (…) → Process Order → Master Data → Order → Define Order Type-Dependent Parameters Double-click on the line for plant 1100 and order type PO##.

2.

On the Master data tab, set the Approval required and Batch record required indicators. Which functions do these indicators have? If required use the field help (F1) to answer this question. _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ Save your settings. a)

Master data tab page: X

Approval required

X

Batch record required

Save your settings.

Task 2: 1.

Assign user status profile PI_APPR, Approved process orders to your order type PO## in Customizing.


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Note: The user status profile determines that you can only withdraw and grant process order approval by setting the corresponding user status. Note that you can define a specific authorization that is required to set a user status. a)

Customizing: (…) → Process Order → Master Data → Order → Define Order Types Double-click on your order type PO##. Status profile: PI_APPR Save the new entry for the order type.

Task 3: 1.

Try to make changes in master recipe T-TAB## (for example, changes to a phase). a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Change Recipe group:T-TAB##

2.

Which message does the system issue? _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

3.

Choose Enter. The operation overview appears. The system issues the following message: You cannot change task list/recipe 1 because of change rule 3.

What do you need to do to make changes to the recipe? _____________________________________________________ _____________________________________________________ _____________________________________________________ a)

You must create an engineering change order to make changes to the recipe. . Making recipe changes using an engineering change order represents an approval procedure for the master recipe. We have dealt with the topic Recipe Approval Using Engineering Change Orders in the training course PLM115, “Basic Data for Process Manufacturing”.

4.

With reference to which change order has the recipe been approved? Display the administrative data of the recipe to answer this question. Continued on next page

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Change number: ___________________________________________ a)

Administrative data tab page Change number: CR##

5.

The recipe describes the production of which material? ______________________________________________________ a)

Recipe header tab page Choose Material assignments Material: T-HTB2## Cetepharm-N tablet

Task 4: 1.

Create a process order of order type PO## for material T-HTB2## in plant 1100. Enter 100 000 PC as the order quantity. a)

Logistics → Production - Process → Process Order → Process Order → Create → With Material Material no.:

T-HTB2##

Production plant:

1100

Process order type:

PO##


100,000 PC

Start:


Enter 2.

Which recipe did the system select for order creation? _____________________________________________________ a)

Master data tab in the order header. The system selected recipe 1 of recipe group T-TAB##.

3.

Which system and user statuses were set with regard to order approval when you created the order? Continued on next page

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_____________________________________________________ _____________________________________________________ _____________________________________________________ a)

Choose the Status icon in the status line. System status: APG Approval granted APRC Based on approved recipe User status: APWD Approval withdrawal locked

4.

Try to change data other than MRP data (for example, make changes to the data of a phase). What do you notice? ______________________________________________________ a)

5.

Changes are not allowed if the order has status APG.

Try to withdraw the order approval. Which message does the system issue? ______________________________________________________ Display the status information for the message. Why can you not withdraw the approval at present? ______________________________________________________ a)

Process order → Functions → Approval → Withdraw approval. The system issues the following message: The business transaction cannot be carried out. Choose Status information. The following message is displayed: User status APWD is active.

6.

Set the user status WDAL Withdr. allowed/no indiv.approv. a)

Choose the Status icon on the status line in the order header. Set the user status WDAL Withdr. allowed/no indiv.approv. The system sets user status WDAL. At the same time, user status APWD is withdrawn.

7.

Withdraw the order approval. Which new system status is set? Continued on next page

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____________________________________________________ _____________________________________________________ Can you now change data other than MRP data? ______________________________________________________ a)

Process order → Functions → Approval → Withdraw approval APNG Approval not granted APRS Approval withdrawn You can now change order data other than MRP data.

8.

Try to release the order. Which message does the system issue? ______________________________________________________ Display the status information for the message. Why can you not release the order at the moment? ______________________________________________________ a)

Choose the Release icon The system issues the following message: The business transaction cannot be carried out. Choose Status information. The following message is displayed: System status APNG is active.

9.

Try to manually approve the order in individual processing. Which message does the system issue? _____________________________________________________ Display the status information for the message. Why can you not approve the order individually at the moment? _____________________________________________________ a)

Process order → Functions → Approval → Individual approval The system issues the following message: The business transaction cannot be carried out. Choose Status information. The following message is displayed: User status WDAL is active.


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10. Set the user status IAAL Individual approval allowed. a)

Choose the Status icon on the status line in the order header. Set the user status IAAL Individual approval allowed. The system sets user status IAAL. At the same time, user status APWD is withdrawn.

11. Individually approve the order. Which new system and user statuses were set after the individual approval? _____________________________________________________ _____________________________________________________ _____________________________________________________ Can you still change data other than MRP data? ______________________________________________________ Finally, save your order and write down the order number. ______________________________________________________ a)

Process order → Functions → Approval → Individual approval System status: APG Approval granted APGS Single approval granted User status: APWD Approval withdrawal locked You cannot change data other than MRP data any more. Save your order and write down the order number.

12. Display your order once again. Display all change documents for the status changes. a)

(…) Process Order → Display Choose the Status icon on the status line. On the Display Status screen, choose: Extras → Change Documents → All.

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Lesson Summary You should now be able to: • Create approved process orders • Change approved process orders

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Lesson: Material Identification and Material Reconciliation Lesson Overview This lesson informs you about the functions of material identification and material reconciliation.


Use the picking function to pack material components into handling units Carry out a completeness check to identify the material components staged Perform quantity reconciliation for the materials involved in the process

Business Example You are a member of the project team implementing the SAP System in a pharmaceutical company. You must make sure that the materials used for production can be uniquely identified at the production line. In addition, you want to be able to carry out reconciliation of the material quantities used and produced after production.

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Lesson: Material Identification and Material Reconciliation

Handling Unit

Figure 166: Handling Unit

A handling unit is always a combination of materials and packaging materials. Packaging materials are materials that close or hold together the packed goods. Furthermore, the packed goods can be packed in or on the packaging material. The packaging material can be a load carrier. Some of the most important packaging materials are boxes, containers, wire baskets, and pallets.

Handling Unit Management • •

Control of logistical processes using handling units Instead of visualizing the movements of individual materials, the movement of the handling units that contain these materials is visualized

You can use handling units in all processes in the supply chain. Handling units contain all inventory management information for the materials packed in them and managed in inventory management. In HU-managed storage locations, all goods movements are performed based on input from the corresponding HUs, and inventory management takes place via the handling units. If you do not work with HU-managed storage locations, you can work with handling units (without inventory information) in delivery and in transportation. In an HU-managed storage location, materials can only be managed in HUs. Packaged and unpackaged materials cannot be managed at the same storage location. If you unpack a material from an HU, the stock of the material is posted at a storage location that is not HU-managed.

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The movability of the handling unit can be restricted in an active quality check. Changes to the stock category due to a successful quality check take place via a posting change of the handling unit. Reporting is available. Although a handling unit always represents the same unit, you can change it by repacking it. A handling unit has a history that describes each business transaction affecting it.

Production Supply

Figure 167: Production Supply

This function visualizes the typical physical material flow from the central storage location to the production lines, resources, and so on. The production supply can be organized using handling units (HUs). This allows you to more easily direct raw materials in production.

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Manual Picking with Process Orders

Figure 168: Manual Picking with Process Orders

You use this function to manually enter packed HUs. You can do the following: • • •

Pack each batch of a material in one or more HUs. Pack several batches of a material or several materials in an HU Pack HUs in other HUs

The following activities are performed: •

• •

You enter the materials, batches, and quantities that will be picked for the process order. The system checks the batches you have entered to see if they meet the required selection criteria. The system uses the selection criteria defined for batch determination for the check. The components that are assigned to the process order but are not yet picked (open reservations) are listed so you can check them. You pack the materials in HUs and can also pack the HUs in higher-level HUs.

It is a good idea to have picking for a process order take place via a separate PI sheet. For the actual production, a second PI sheet should be generated.

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Automatic Picking with Process Orders

Figure 169: Automatic Picking with Process Orders

You use this function when materials are picked for a process order using an external weighing system. The materials required for the process order are weighed, filled, or measured and packed in handling units. The messages from the external weighing system are transferred to the SAP ECC System via the PI-PCS interface.

Material Identification (I)

Figure 170: Material Identification (I)

You can use this function to identify and verify ingredients at the production line. The ingredients must be staged as pick-HUs.

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Material Identification (II)

Figure 171: Material Identification (II)

Material identification is performed in the PI sheet using dynamic function calls. It comprises the following functions: • • • • •

Completeness check Sequence check Automatic goods issue posting (GI-posting) after successful completeness or sequence check Automatic transfer of data from material identification to the batch record Check that picking is complete

You use the completeness check to ensure that the HUs that were picked for the process order are staged at the production line. You use the sequence check to ensure that the sequence of the components to be used is correct. You can perform a completeness check or sequence check at the start of: • •

Production for the whole process order An operation or phase

The goods issue posting for the components is carried out at HU level.

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Material Reconciliation

Figure 172: Material Reconciliation

You use this function to analyze and verify the ingredients and yield at the end of the production process. By checking the yield and reconciliating the quantities of the ingredients, you can ensure that there are no invalid inconsistencies between the ingredients and the yield. The goods movements for the process order form the basis for material reconciliation, for example, all goods receipts with all returns and all reversals, as well as all goods withdrawals with all returns and all reversals.

Material Identification and Material Reconciliation: Topic Summary • • •

698

A picking function for packing material components in handling units is available. You can use the material identification functions to check the completeness and sequence of the material components staged. Using material reconciliation, you can ensure that there are no invalid quantity inconsistencies with regard to the materials involved in the process.


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Exercise 42: Material Identification Exercise Objectives After completing this exercise, you will be able to: • Perform picking in handling units • Perform a material identification / completeness check

Business Example You can use the Material Identification function to check whether the material that was picked for the process order is completely available at the production line and will be used in the correct sequence. In the first PI sheet, you will pick the material components of your process order in handling units. In the second PI sheet, you will then use the completeness check to identify the handling units staged at the production line.

Task 1: Preparation: 1.

Post a goods issue for material T-HTB1##. Use movement type 501. Post 1,000,000 g in storage location 0002 of plant 1100. Enter the value 134°C for the batch characteristic melting point.


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Task 2: Release the process order for material T-HTB2## that you created for the previous topic for production and create the control recipes for the order.

Task 3: Select the control recipes for the order in the control recipe monitor. The system created four control recipes for the different areas in the plant. Send the four control recipes.

Task 4: Find and maintain the PI sheet for control recipe destination Scales for your order. Important: Carefully select the PI sheet by entering your order number to avoid interferences with the other course participants. 1.

First, maintain phase 110 by executing the required digital signatures. If you try to execute the signatures in a sequence different to the one defined, the system will issue an error message. You cannot process phase 120 until phase 110 has been processed completely.

2.

In phase 120, you can call up document SOP 123-01 for more information about the weighing instructions. Then pick the required material components in handling units. Note the details described in the solutions for this exercise. Execute your signature to confirm the successful picking.

3.

Maintain phase 130. If you want, you can enter a long text, which would then be displayed in the next PI sheet.

4.

Exit the PI sheet when you have maintained it completely.

Task 5: Select the messages that have been created for the order so far and send them.

Task 6: Now maintain the PI sheet for control recipe destination Granulating for your order. 1.

Maintain phase 210. Note that the long text you entered in the previous PI sheet is now displayed. Continued on next page

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2.

In phase 220, in the material reconciliation carry out a completeness check for the materials staged. Note the details described in the solutions for this exercise. Execute your signature to confirm the successful material identification.

3.

You do not necessarily need to maintain the PI sheet further. The next process steps comprise different other PI sheet functions, such as: - Time calculations - Processing input tables - Input validations - Process data calculations Exit the PI sheet.

Task 7: Select the messages that have been created by maintaining the two PI sheets in the message monitor and send them.

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Solution 42: Material Identification Task 1: Preparation: 1.

Post a goods issue for material T-HTB1##. Use movement type 501. Post 1,000,000 g in storage location 0002 of plant 1100. Enter the value 134°C for the batch characteristic melting point. a)

Logistics → Materials Management → Inventory Management → Goods Movement → Goods Receipt → Other Movement type

501

Plant:

1100

Storage location:

0002

Material:

T-HTB1##

Quantity:

1,000,000 g

Melting point:

134°C

Task 2: Release the process order for material T-HTB2## that you created for the previous topic for production and create the control recipes for the order.

Task 3: Select the control recipes for the order in the control recipe monitor. The system created four control recipes for the different areas in the plant. Send the four control recipes.

Task 4: Find and maintain the PI sheet for control recipe destination Scales for your order. Important: Carefully select the PI sheet by entering your order number to avoid interferences with the other course participants. 1.

First, maintain phase 110 by executing the required digital signatures. Continued on next page

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If you try to execute the signatures in a sequence different to the one defined, the system will issue an error message. You cannot process phase 120 until phase 110 has been processed completely. a) 2.


In phase 120, you can call up document SOP 123-01 for more information about the weighing instructions. Then pick the required material components in handling units. Note the details described in the solutions for this exercise. Execute your signature to confirm the successful picking. a)

Picking: Choose Picking. The Picking for Manufacturing Order screen appears. Choose the Open reservations tab. Select all reservation items with a requirement quantity not equal to zero. Choose Copy. The Materials tab appears. The reservations you selected were copied. Select the line with a reservation and choose the Selection of valid packing mat. icon. The stainless steel container T-VERP199 is proposed as the packaging material. Use the proposed packaging material. Now choose Pack for all four reservations one after the other. The system assigns an HU number to every reservation number. Save your picking.

3.

Maintain phase 130. If you want, you can enter a long text, which would then be displayed in the next PI sheet. a)

4.


Exit the PI sheet when you have maintained it completely. a)



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Task 5: Select the messages that have been created for the order so far and send them.

Task 6: Now maintain the PI sheet for control recipe destination Granulating for your order. 1.

Maintain phase 210. Note that the long text you entered in the previous PI sheet is now displayed. a)

2.


In phase 220, in the material reconciliation carry out a completeness check for the materials staged. Note the details described in the solutions for this exercise. Execute your signature to confirm the successful material identification. a)

Material identification / completeness check: Choose Completeness check. The Material Identification: Completeness screen appears. First, check picking by choosing Check picking. Then enter any number in the Handling unit field and choose Enter to confirm. The following message appears: Handling unit not relevant for order/operation. Now enter the HU number assigned by the system for every material in the Handling unit field. Choose Enter to confirm each entry. A green checkmark in the Status field for the material component shows the successful identification. Save your completeness check.

3.

You do not necessarily need to maintain the PI sheet further. The next process steps comprise different other PI sheet functions, such as:


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- Time calculations - Processing input tables - Input validations - Process data calculations Exit the PI sheet. a)


Task 7: Select the messages that have been created by maintaining the two PI sheets in the message monitor and send them.

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Lesson Summary You should now be able to: • Use the picking function to pack material components into handling units • Carry out a completeness check to identify the material components staged • Perform quantity reconciliation for the materials involved in the process

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Lesson: Integration with Quality Management

Lesson: Integration with Quality Management Lesson Overview This lesson informs you about the in-process quality inspection.


Outline the main steps that must be followed in master data maintenance to carry out an in-process quality inspection Describe the functions of inspection lots and create an inspection lot for in-process quality inspection Describe possible scenarios of an in-process quality inspection Carry out in-process quality inspections with batch value assignment

Business Example As a member of the SAP project team, you will test the functions for quality inspection in production. You will create an inspection lot with reference to a process order and carry out in-process quality inspections. In this context, you will test the simultaneous value assignment to batches you have produced.

Quality Inspections in Production

Figure 173: Quality Inspections in Production

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In production, you can check the product quality at the following points in time: • •

During the production process When the product is delivered to the warehouse

Inspection Lot

Figure 174: Inspection Lot

The functions of quality inspection of the ECC System are fully integrated into the entire logistics process. They affect all business activities (such as product planning, production, procurement, sales). A quality inspection can only be carried out if an inspection lot is created. Inspection lots document the entire inspection process, from inspection specifications over inspection results recording, up to the usage decision. They can be created automatically or manually for the corresponding application. During in-process inspection taking place in parallel to the production process, the inspection lot is either created manually or automatically from within the process order when you release the order. The inspection requests are maintained for the operations or phases of the master recipe the process order is based on. They are then transferred to the inspection lot. Inspection results are recorded for the inspection characteristics of the inspection lot when the process order is carried out. In other tasks, such as a goods receipt (post-process inspection), the inspection lot is created on the basis of an inspection plan maintained in ECC QM. Inspection plans are master data of ECC QM.

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In-Process Inspection: Inspection Lot

Figure 175: In-Process Inspection: Inspection Lot

In an in-process quality inspection, the inspection lot is created on the basis of the master recipe on which the the process order is based. In the master recipe, you maintain inspection specifications in the form of inspection characteristics for the corresponding operations or phases. You can either create the inspection lot manually or the system creates it automatically when you release the process order. For the system to be able to do so, you must activate an inspection type In-process insp. for production orders in the material master of the material to be produced. The inspection characteristics for the operations or phases of the master recipe are then transferred to the corresponding inspection operations of the inspection lot. Later, you can also add unplanned inspection characteristics from within the process order.

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Inspection at Goods Receipt: Inspection Lot

Figure 176: Inspection at Goods Receipt: Inspection Lot

You can also check the product quality for a goods receipt from production. In this case, an inspection lot is created based on an inspection plan maintained in ECC QM. Inspection plans are master data of ECC QM. For goods receipt quality inspections, you must activate an inspection type Goods Receipt Inspection for Order in the material master record.

Inspection Processing

Figure 177: Inspection Processing

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The recording of inspection results is carried out by recording the inspection results for the inspection values assigned to the inspection lot. After the results of an inspection are recorded, the inspection characteristics must be valuated. Valuation can be carried out automatically or manually. Different kinds of valuation procedures are available for this. Depending on the valuation, the characteristics are accepted or rejected. Quality inspection is completed when you have made a usage decision for the entire inspection lot.

In-Process Inspection: Scenarios

Figure 178: In-Process Inspection: Scenarios

There are several ways to record inspection results in an in-process quality inspection: 1. 2. 3.

4.

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Inspection results can be recorded by sending process messages from a process control system or a PI sheet. From within the PI sheet, you can directly navigate to QM Inspection Results Recording. An interface is available to link external laboratory information systems (LIMS) to ECC Quality Management. ECC QM uses this interface to transfer process instructions to the LIMS, which, in return, sends inspection results back to ECC QM. You can also use the corresponding transactions of ECC QM to record inspection results during the production process.


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Recording Inspection Results in the PI Sheet

Figure 179: Recording Inspection Results in the PI Sheet

If the control recipe contains an inspection results request, the Record inspection results pushbutton is displayed in the PI sheet. By double-clicking this pushbutton, you can navigate to inspection results recording of QM. The system calls the inspection characteristics for the phase contained in the inspection results request.

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Specification of Batches Produced

Figure 180: Specification of Batches Produced

In this example, a quality inspection is planned for operation "Mixing". The inspection results are recorded in the inspection lot for the assigned inspection characteristics. If the product is to be handled in batches, inspection results can be used for a usage decision or inspection point completion by automatically copying them to the class characteristics of the batch produced.

Integration with Quality Management: Topic Summary In production, you can carry out quality inspections as in-process inspections or as goods receipt inspections. You can use the inspection results for batch specification by automatically copying them to the characteristics of the batch produced.

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Exercise 43: Integration with Quality Management Exercise Objectives After completing this exercise, you will be able to: • Explain the following master data: inspection type, inspection characteristics, material specification • Create an inspection lot • Describe scenarios of in-process quality inspection • Perform inspection results recording by using the corresponding transaction of ECC Quality Management • Perform an inspection results recording from the PI sheet • Check the specification of batches produced

Business Example You will get an overview of the master data that needs to be maintained for in-process quality inspection. You will learn about the function of an inspection lot. You will get an overview of possible scenarios of in-process quality inspections in PP-PI. You will test the function of an in-process quality inspection in two different scenarios: First, you will carry out inspection results recording from ECC Quality Management and then you will record inspection results from within the PI sheet. You will make sure that the quality inspection results in the batches produced are being valuated.

Task 1: 1.

Display the Quality Management view for material T-HTB2## in plant 1100.

2.

Display the inspection data. Which inspection type has been assigned to the material? _____________________________________________________


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3.

Which function does this inspection type have?

4.

Go to the Classification view.

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Which class of class type 023 Batch has been assigned to the material? ______________________________________________________ Which characteristics have been allocated to the class? ______________________________________________________

Task 2: 1.

Display the operation overview of your master recipe T-TAB##.

2.

Inspection characteristics for an in-process quality inspection have been maintained for phase 320. Write down the inspection characteristics: _____________________________________________________ _____________________________________________________

Task 3: 1.

Display the material specification for material T-HTB2##.


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2.

Which QM master inspection characteristic has been assigned to the batch characteristic of the material?

3.

Which function does this assignment have?

Task 4: 1.

Access your current process order for material T-HTB2## in the display mode.

2.

Which system status has been set with regard to an in-process quality inspection when you released the order?

3.

Display the number of the assigned inspection lot on the Assignment order header screen. Write down the inspection lot number: ______________________________________________________

Task 5: 1.

Describe the various scenarios of in-process quality inspection in PP-PI. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Continued on next page

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____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

Task 6: Scenario: Inspection results recording by using the corresponding transaction of ECC Quality Management 1.

Access results recording via the worklist for quality inspection. Enter the material number to select your inspection lot.

2.

Take a look at the inspection operation and inspection characteristic structure of your inspection lot.

3.

Enter results for an inspection point. Enter 1st insp. point as the inspection point identification.

4.

Enter the following inspection results in the characteristic overview: Water content:

1,1 %

Active ingredient content:

98 %

Choose Enter to confirm your entries and save your inspection results.

Task 7: 1.

Display your batch for material T-HTB2##.

2.

Display the batch classification data. What do you notice? _____________________________________________________ _____________________________________________________ _____________________________________________________ Write down the active ingredient content: ________________________________


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Task 8: Scenario: Jumping to inspection results recording from the PI sheet. Now maintain the PI sheet for control recipe destination Laboratory for your order. 1.

Maintain phase 310. Note: You can use a hyperlink or function call to display the instructions for inspection preparation. In the first case, the instruction is displayed in a separate frame within the PI sheet.

2.

Maintain phase 320. Perform results recording. On the initial screen of inspection point recording, choose inspection point identification 2nd inspection point. Enter the following inspection results in the characteristic overview: Water content: 1,1 % Active ingredient content: 97 % Choose Enter to confirm your entries and save your inspection results.

3.

Maintain the other steps in the PI sheet. Exit the PI sheet.

Task 9: Select the process messages that have been created by maintaining the PI sheet in the message monitor and send them.

Task 10: 1.

Display your batch for material T-HTB2## again.

2.

Display the batch classification data. What do you notice? _____________________________________________________ _____________________________________________________ Write down the active ingredient content: ________________________________

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Solution 43: Integration with Quality Management Task 1: 1.

Display the Quality Management view for material T-HTB2## in plant 1100. a)

Logistics → Production - Process → Master Data → Material Master → Material → Display → Display Current Material: T-HTB2## Enter Choose Quality Management. Enter Choose plant 1100. Enter

2.

Display the inspection data. Which inspection type has been assigned to the material? _____________________________________________________ a)

Choose Insp. setup. InspType: 03 In-Process Insp. for Production Order

3.

Which function does this inspection type have? Answer: The inspection type enables you to create an inspection lot for in-process quality inspection. For more information, see the page “„In-Process Inspection: Inspection Lot” in your participant handbook.

4.

Go to the Classification view. Which class of class type 023 Batch has been assigned to the material? ______________________________________________________ Which characteristics have been allocated to the class?


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______________________________________________________ a)

Classification view Choose class type 023 Batch. Class:

N-005 Tablet characteristics

Characteristic:

Active ingredient content

Task 2: 1.

Display the operation overview of your master recipe T-TAB##. a)

Logistics → Production - Process → Master Data → Master Recipes → Recipe and Material List → Display Recipe group: T-TAB##

2.

Inspection characteristics for an in-process quality inspection have been maintained for phase 320. Write down the inspection characteristics: _____________________________________________________ _____________________________________________________ a)

Choose Enter. The operation overview appears. Select the line for phase 320 and choose the Inspection characteristic icon in the toolbar at the bottom of the screen. Master inspection characteristics: N-200

Water content

N-300

Active ingredient content

Task 3: 1.

Display the material specification for material T-HTB2##. a)

(…) → Material Master → Environment → QM Maintenance Functions → Display Material Specification Material: T-HTB2## Enter Continued on next page

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Which QM master inspection characteristic has been assigned to the batch characteristic of the material? Answer: The QM master inspection characteristic N-300 Active ingredient content has been assigned to batch characteristic N-006 Active ingredient content.

3.

Which function does this assignment have? Answer: The inspection results for the QM characteristic are automatically used to assign a value to the class characteristics of the batch produced.

Task 4: 1.

Access your current process order for material T-HTB2## in the display mode. a)

2.

(…) Process Order → Display

Which system status has been set with regard to an in-process quality inspection when you released the order? Answer: ILAS Inspection lot assigned

3.

Display the number of the assigned inspection lot on the Assignment order header screen. Write down the inspection lot number: ______________________________________________________ a)

Choose the Assignments tab in the order header. Write down the inspection lot number.

Task 5: 1.

Describe the various scenarios of in-process quality inspection in PP-PI. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Continued on next page

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____________________________________________________________ a)

For information on the scenarios of in-process quality inspection, see the page “„In-Process Inspection: Scenarios” in your participant handbook.

Task 6: Scenario: Inspection results recording by using the corresponding transaction of ECC Quality Management 1.

Access results recording via the worklist for quality inspection. Enter the material number to select your inspection lot. a)

Logistics → Quality Management → Quality Inspection → Worklist → Results Recording Material: T-HTB2## Execute (F8) icon

2.

Take a look at the inspection operation and inspection characteristic structure of your inspection lot. a)

The Inspection Point screen appears. The system selects your inspection lot for material T-HTB2## and displays the relevant elements in a tree hierarchy.

3.

Enter results for an inspection point. Enter 1st insp. point as the inspection point identification. a)

Inspection point: Identification: 1st inspection point

4.

Enter the following inspection results in the characteristic overview: Water content:

1,1 %


98 %


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Choose Enter to confirm your entries and save your inspection results. a)

Choose Enter. The characteristics overview appears. Enter the following inspection results: Water content:

1,1 %


98 %

Choose Enter to confirm your entries and save your inspection results.

Task 7: 1.

Display your batch for material T-HTB2##. a)

(…) → Material Master → Batch → Display Material:

T-HTB2##

Batch:

Batch number (if required, use F4 to select)

Enter 2.

Display the batch classification data. What do you notice? _____________________________________________________ _____________________________________________________ _____________________________________________________ Write down the active ingredient content: ________________________________ a)

Choose the Classification tab. The inspection result you have recorded for the active ingredient content is used as the value for the batch characteristic. Active ingredient content: 98 %

Task 8: Scenario: Jumping to inspection results recording from the PI sheet. Now maintain the PI sheet for control recipe destination Laboratory for your order. 1.

Maintain phase 310. Continued on next page

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Note: You can use a hyperlink or function call to display the instructions for inspection preparation. In the first case, the instruction is displayed in a separate frame within the PI sheet. a) 2.


Maintain phase 320. Perform results recording. On the initial screen of inspection point recording, choose inspection point identification 2nd inspection point. Enter the following inspection results in the characteristic overview: Water content: 1,1 % Active ingredient content: 97 % Choose Enter to confirm your entries and save your inspection results. a)

Choose Inspection Results Recording. Identification: 2nd inspection point Choose Enter. The characteristics overview appears. Enter the following inspection results: Water content: 1.1 % Active ingredient content: 97 % Choose Enter to confirm your entries. The inspection characteristics must have status 5 Processing completed. Save your inspection results.

3.

Maintain the other steps in the PI sheet. Exit the PI sheet. a)



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Task 9: Select the process messages that have been created by maintaining the PI sheet in the message monitor and send them.

Task 10: 1.

Display your batch for material T-HTB2## again. a)

(…) → Material Master → Batch → Display Material: T-HTB2## Batch: Batch number (if required, use F4 to select) Enter

2.

Display the batch classification data. What do you notice? _____________________________________________________ _____________________________________________________ Write down the active ingredient content: ________________________________ a)

Choose the Classification tab. The inspection result you have recorded for the active ingredient content is used as the value for the batch characteristic. Active ingredient content: 97 %

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Exercise 44: Material Reconciliation Exercise Objectives After completing this exercise, you will be able to: • Perform a material reconciliation

Business Example Using the Material reconciliation function, you can ensure that there are no invalid quantity inconsistencies with regard to the materials involved in the process. The basis for material reconciliation is, for example, the goods movements for the process order. After all goods movements have been made for your process order you will call up the material reconciliation function for your order in your last PI sheet. You will get an overview of the information that material reconciliation provides.

Task 1: Maintain the PI sheet for control recipe destination Tablet press for your order. 1.

First, maintain phases 410 and 420.

2.

Maintain phase 430. Report a produced quantity of 100 000 PC and execute your signature to confirm the entry. Caution: Do not maintain the PI sheet any further for the time being.

Task 2: In a second session, select the process messages that the system created while you maintained the current PI sheet and send them. Note: Message category PROD results in a goods receipt posting for the batch of material T-HTB2## produced.

Task 3: Maintain your PI sheet further. 1.

Carry out material reconciliation for your order by choosing the relevant function key. The general data about the process order is displayed in the material reconciliation header. Continued on next page

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It contains, for example, the goods receipt quantities for your product T-HTB2## (100 000 PC) and the results of reconciliation for your four material components. 4 materials OK / 0 materials not OK A legend below the header explains the different icons. Below the legend, a list with the material components is displayed. Your material components should have status Material OK. To display detail information on the components (inspection formula, material movements, ...), double-click the corresponding line in the list. For information on the goods movements of the product, choose the Header mat. movements (F6) icon. 2. Hint: You do not necessarily need to maintain the PI sheet any further.

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Solution 44: Material Reconciliation Task 1: Maintain the PI sheet for control recipe destination Tablet press for your order. 1.

First, maintain phases 410 and 420. a)

2.


Maintain phase 430. Report a produced quantity of 100 000 PC and execute your signature to confirm the entry. Caution: Do not maintain the PI sheet any further for the time being. a)


Task 2: In a second session, select the process messages that the system created while you maintained the current PI sheet and send them. Note: Message category PROD results in a goods receipt posting for the batch of material T-HTB2## produced.

Task 3: Maintain your PI sheet further. 1.

Carry out material reconciliation for your order by choosing the relevant function key. The general data about the process order is displayed in the material reconciliation header. It contains, for example, the goods receipt quantities for your product T-HTB2## (100 000 PC) and the results of reconciliation for your four material components. 4 materials OK / 0 materials not OK A legend below the header explains the different icons. Below the legend, a list with the material components is displayed. Your material components should have status Material OK. To display detail information on the components (inspection formula, material movements, ...), double-click the corresponding line in the list.


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For information on the goods movements of the product, choose the Header mat. movements (F6) icon. a)


2. Hint: You do not necessarily need to maintain the PI sheet any further. a)

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Lesson Summary You should now be able to: • Outline the main steps that must be followed in master data maintenance to carry out an in-process quality inspection • Describe the functions of inspection lots and create an inspection lot for in-process quality inspection • Describe possible scenarios of an in-process quality inspection • Carry out in-process quality inspections with batch value assignment

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Lesson: Batch Record Lesson Overview This lesson informs you about the batch record function.


Describe the structure and process of editing a batch record Explain the status profile and version management for batch records Explain how you can influence batch status management and the usage decision for an inspection lot

Business Example You are a member of the SAP project team in a pharmaceutical company. To comply with legal requirements, you have to guarantee that all quality-relevant data about the manufacturing process of a batch can be compiled and archived in a batch record. To be able to do so, you will get an overview of the functions available in process data documentation for the creation of batch records in the ECC System.

Batch Record

Figure 181: Process Order Completion: Batch Record

When setting up the system for production in compliance with GMP, you can define that as a prerequisite for order archiving and deletion a batch record must be created and approved.

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Lesson: Batch Record

Process Data Documentation

Figure 182: Process Data Documentation

Process data documentation is part of the Production Planning for Process Industries (PP-PI) component. You can use it to create lists of quality-relevant data and write them to an optical archive. In process data documentation, you can archive the following records: •

Order records: –

•

They contain all quality-relevant ECC data collected around a process order. Batch records: – –

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They contain all quality-relevant data on the production of a batch. The structure, contents, and processing of batch records comply with international standards that are laid down in the guidelines on Good Manufacturing Practices (GMP) for the pharmaceutical and food industries.


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Batch Record

Figure 183: Batch Record

In the Production Planning for Process Industries (PP-PI) application component in the ECC System, you can create, optically archive, and approve batch records to document the production and processing of your batches. In this way, you comply with one of the main requirements laid down in the guidelines on Good Manufacturing Practices (GMP) for the pharmaceutical industry. To be able to create a batch record for a batch, the Batch record required indicator must have been set in the order types of the process orders in question.

Batch Record: Structure

Figure 184: Batch Record: Structure

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A batch record consists of a current, valid version and possibly a history. A history documents older versions that became invalid when the batch record was changed or added to after it had been approved. All versions are managed in the header record of the batch record along with their statuses. At most, the batch record version can contain all of the following: • • •

• • • •

One document for the table of contents and the version data of the batch record respectively One document in which the deviations that occurred during batch processing are listed Documents for the following ECC objects: All process orders to which the batch has been assigned, the material lists of these process orders, the PI sheets of the process orders, the process messages for the process orders, all inspection lots for the batch One document for user-defined data in which you can combine further ECC data according to your company's requirements One attachment with archive files from external systems, raw data from the process control system, or labels The comments entered for the version The digital signatures executed during approval

Batch Record Processing

Figure 185: Batch Record Processing

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Status and Versions of a Batch Record

Figure 186: Status and Versions of a Batch Record

Batch Status and Usage Decision

Figure 187: Batch Status and Usage Decision

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If required, you can specify in the material master (Work Scheduling view) that the following transactions can only be carried out for certain materials after the batch record has been approved: • •

Making the usage decision for the incoming inspection lot of the batch Changing the batch status from Restricted to Unrestricted

Batch Record: Summary In the Production Planning for Process Industries (PP-PI) application component in the ECC System, you can create, optically archive, and approve batch records to document the production and processing of your batches. In this way, you comply with one of the main requirements laid down in the guidelines on Good Manufacturing Practices (GMP) for the pharmaceutical industry.

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Exercise 45: Batch Record Exercise Objectives After completing this exercise, you will be able to: • Explain the structure and content of a batch record • Describe batch record processing • Explain the structure and content of a batch record • Generate and display a batch record

Business Example You will become familiar with the function of process data documentation. You will become familiar with the structure, contents, and usual procedure for processing a batch record. You will also become familiar with the status profile and version management of a batch record. You will then generate a batch record and display, for example, the lists of ECC data.

Task 1: 1.

Describe the function of process data documentation. Which records can be generated and archived in process data documentation? What data do these records contain? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 2: 1.

Describe the structure and content of a batch record. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ Continued on next page

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___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 3: 1.

Outline the typical process of batch record creation. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 4: 1.

Explain the status profile and version management for batch records. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

Task 5: 1.

In the previous topics, you processed a process order for the production of material T-HTB2## by means of four PI sheets. Display this process order.

2.

Which batch number was assigned for product T-HTB2## in the order? Write down the batch number: __________________________

3.

Which status was set to require the creation of a batch record? Status: ________________________________________________

4.

What effect does this status have on further order processing?


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_____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ 5.

Based on which Customizing setting was this status set? ______________________________________________________

Task 6: 1.

Generate the batch record for the batch of material T-HTB2##.

Task 7: 1. 2.

Display the batch record for the batch. Which status does the batch record have at this time? ______________________________________________________

3.

Display the print lists for the following ECC objects by choosing the corresponding context menu: - Process order - Material list - Process messages - PI sheet - Inspection lot

4.

Switch to the change mode in the batch record and carry out deviation recording. As deviations the system lists, for example, the values outside of the tolerances entered in the PI sheet.

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Solution 45: Batch Record Task 1: 1.

Describe the function of process data documentation. Which records can be generated and archived in process data documentation? What data do these records contain? ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

To answer these questions, see the page Process Data Documentation in your participant handbook.

Task 2: 1.

Describe the structure and content of a batch record. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

To answer this question, see the page Batch Record: Structure in your participant handbook.

Task 3: 1.

Outline the typical process of batch record creation. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________


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___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

To answer this question, see the page Batch Record Processing in your participant handbook.

Task 4: 1.

Explain the status profile and version management for batch records. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ a)

To answer this question, see the page Status and Versions of a Batch Record in your participant handbook.

Task 5: 1.

In the previous topics, you processed a process order for the production of material T-HTB2## by means of four PI sheets. Display this process order. a)

2.

(…) Process Order → Display

Which batch number was assigned for product T-HTB2## in the order? Write down the batch number: __________________________ a)

3.

On the order header, choose the Goods receipt tab.

Which status was set to require the creation of a batch record? Status: ________________________________________________ a)

Choose the Status icon in the status line. Status: BRRQ Batch record required

4.

What effect does this status have on further order processing?


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_____________________________________________________ _____________________________________________________ _____________________________________________________ _____________________________________________________ a) 5.

The order cannot be archived for the produced batch until a batch record has been created.

Based on which Customizing setting was this status set? ______________________________________________________ a)

In the order type-dependent parameters for your order type PO##, the Batch record required indicator was set.

Task 6: 1.

Generate the batch record for the batch of material T-HTB2##. a)

Logistics → Production-Process → Process Order → Tools → Process Data Document → Batch Record The Batch Record: Create Worklist screen appears. Batch:

batch number

Material number:

T-HTB2##

Plant:

1100

X

Generate

Batch Record → Execute Or choose Generate worklist (F8). The Generate Batch Record screen appears. Position the cursor on the batch number and choose Batch Record. The Batch Record: Create Worklist screen appears and the system issues the following message: Batch record generated.


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Task 7: 1.

Display the batch record for the batch. a)

On the Batch Record: Create Worklist screen, choose: Batch:

batch number

Material number:

T-HTB2##

Plant:

1100

X

Display/change

Batch Record → Execute. Or choose Generate worklist (F8). The Display Batch Record screen appears. 2.

Which status does the batch record have at this time? ______________________________________________________ a)

3.

System status: Batch record created

Display the print lists for the following ECC objects by choosing the corresponding context menu: - Process order - Material list - Process messages - PI sheet


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- Inspection lot a)

Expand the entire tree structure for the batch record. Display the data for the process order: Position the cursor on the process order number and click the right mouse button. The context menu appears. In the context menu, choose Display print preview. Display the data for the material list: Position the cursor on Material list and click the right mouse button. The context menu appears. In the context menu, choose Display print preview. Display the data for the process messages: Position the cursor on Process messages and click the right mouse button. The context menu appears. In the context menu, choose Display print preview. Display the data for the PI sheets: Position the cursor on the number of a PI sheet and click the right mouse button. The context menu appears. In the context menu, choose Display print preview. Hint: A special layout is used to display PI sheets for batch records. Display the data for the inspection lot: Position the cursor on the inspection lot number and click the right mouse button. The context menu appears. In the context menu, choose Display print preview.

4.

Switch to the change mode in the batch record and carry out deviation recording. As deviations the system lists, for example, the values outside of the tolerances entered in the PI sheet. a)

Choose the Switch Between Change Mode and Display Mode icon. Choose Deviations.

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Lesson Summary You should now be able to: • Describe the structure and process of editing a batch record • Explain the status profile and version management for batch records • Explain how you can influence batch status management and the usage decision for an inspection lot

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Lesson: Batch Derivation Lesson Overview This lesson informs you about the batch derivation function.


•

Describe how you can use batch derivation to transfer values from batch attributes in the batch where-used list for component batches to batches of a finished product Name the settings required in Customizing and in the application

Business Example You want to use the batch derivation function to transfer batch master data and classification data from component batches that went into batches you produced.

Uses of the Batch Derivation

Figure 188: Uses of the Batch Derivation

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Lesson: Batch Derivation

You can use batch derivation to transfer, offer for selection, or display, batch master data and classification data from component batches that went into batches you produced. It always applies that: • • •

Component batches can be senders of data (components B, D, G) Produced batches can be receivers of data (components B, A) A component can be a sender and a receiver (component B)

To be able to derive batch data, you must have set up the batch where-used list. The BaWU synchron.postng indicator must be set in the Customizing of the batch where-used list. The derivation functions along the batch where-used list, which means that only those component batches are used that went into the batch produced. In the evaluation of the batch where-used list, both existing and planned goods movements are considered. The batch derivation is performed with the help of the condition technique. You maintain the receiver-sender relationships in the strategy records of the batch derivation application or in the BOM for selected BOM items. Restrictions: • •

It is not possible to transfer from a produced batch to a component batch. In the standard system you cannot make derivations in connection with collective orders, because the batch where-used list cannot evaluate the links.

Pull Derivation / Push Derivation

Figure 189: Pull Derivation / Push Derivation

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Derivation direction: Depending on the actual case, it makes sense to start the derivation of the charge data from a component or a product. However, the values are always transferred from the component to the product - that is, synchronous with the direction of the quantity flow: • •

Pull derivation (1 receiver, n senders) Push derivation (n receivers, 1 sender)

Callup Points of the Batch Derivation

Figure 190: Callup Points of the Batch Derivation

The batch derivation function is in the SAP Standard System from release 4.7 and is available from release 4.6c. The derivation can be called up and used at fixed points in all areas of Logistics. • • •

When posting goods receipts for manufacturing orders When releasing process and production orders When making the usage decision

The derivation can also be performed before the archiving and approval of the batch record. It is recommended to perform the batch derivation as late as possible.

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Along with the derivation callup points named along the supply chain, you can specify that derivations can be performed manually, independently of a fixed callup point. It is also possible to define user-specific callup points for derivations. A user exit (EXIT_SAPLDRVN_00) or the BADI DERIVATION are available for you to determine the sender. You start the manual derivation with a transaction (DVMAN) that is located in the SAP Standard Menu of the batch management in the Enterprise release.

Application Example: Filling

Figure 191: Application Example: Filling

The derivation of batch data can be used in the following scenarios, among others: •

•

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Filling: A batch of a material is produced and filled into different containers before the results of the quality inspection are available. If the bulk batch is specified, these results are to be transferred to the container batches. This request can be represented by a push derivation, whereby the specifications of a batch are transferred to a number of receiver batches.


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Application Example: Pick and Pack Activities

Figure 192: Application Example: Pick and Pack Activities

The derivation of batch data can be used in the following scenarios, among others: •

•

752

Pick and pack activities: The expiry data of the unpacked material is to be transferred to the packed material. The label printing for packing the final product is usually done before the expiry date can be determined via the goods receipt from production. The derivation can be used to determine the expiry date before the goods receipt from production and thus printed on the packing label. The derivation can also be used to check whether the expiry date on the packing is not after the date on the incoming components.


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Batch Derivation Customizing - Condition Technique

Figure 193: Batch Derivation Customizing - Condition Technique

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To use the Derivations component, you must make the following settings in sequence in Customizing: • •

• •

Activate the derivation. For releases before 4.7, you can alternatively start a report to activate the batch derivation. Maintain the number ranges for the derivation numbers and condition record numbers for the number range objects DRVNO (derivation number) and KONR (condition record number). By maintaining the condition technique you define which criteria the system uses to create condition records for the batch derivations. Specify the derivation callup points and the derivation: –

–

–

754

Dynamic derivation for simulation: In the dynamic derivation there is no transfer of attributes to the receiver batch(es). The derivation is simulated to check the batch attributes, for example. The result of the derivation, or the values, are only displayed. The derivation is saved, but the receiver batch(es) are not automatically changed. Static derivation: In a static derivation, the values are transferred from sender batches to receiver batches in accordance with the receiver-sender relationships and the rules of the derivation. In the static derivation there is a transfer of the determined attributes of the sender batch(es) to the receiver batch(es). Control derivation window: You use this field to control whether the result of the derivation is displayed in a separate window. This window informs you that there has been a derivation and whether any errors or warnings appeared. You can also branch from this window to the detailed display of the derivation. The window also allows you to interrupt the operation that triggered the derivation (for example, save, release).


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Condition Record Maintenance for Receivers

Figure 194: Condition Record Maintenance for Receivers

You can maintain the condition records for receivers and senders in the derivation application, or you can maintain them using the condition record maintenance of the BOMs. The condition records are maintained separately for receiver and sender materials. To maintain the receiver condition records in the derivation application (transaction DVR1), you select the condition type defined in Customizing or a suitable key combination and store rules for the derivation for each condition record and assigned field or charge characteristic. •

• •

•

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Sender field empty: You can use this setting to control whether the system outputs a warning or error message if the attribute being transferred does not have a value. Overwrite receiver: With this setting you specify whether or not a warning or error message is output before attribute values are overwritten. Steps in batch where-used list: With this entry you can limit the number of steps that are triggered in the batch where-used list within a top-down analysis in the batch derivation. Orders and purchase orders are not counted here. You set the Save messages indicator to record the messages.


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Condition Record Maintenance for Senders

Figure 195: Condition Record Maintenance for Senders

To maintain the sender condition records (transaction DVS1), you select the condition type defined in Customizing or a suitable key combination, such as material number, material type or receiver and sender material, and material type of sender. In the first case you enter a material number for the material that will function as the receiver. In the data maintenance you store all the fields (batch master record) or batch characteristics that are to be transferred automatically from the sender to the receiver. For example, you can select the expiry date (field: VFDAT or LOBM_VFDAT), the manufacturing date (HSDAT or a batch characteristic defined as an object characteristic ZLOBM_HSDAT), the usage decision code (LOBM_UDCODE) or a freely definable characteristic (such as ZBM_LAND). To delete condition records, you set the deletion indicator. If you set the push derivation indicator, the system performs a push derivation. The indicator can only be set for condition records for which the sender is not also the receiver.

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Condition Record Maintenance for the BOM

Figure 196: Condition Record Maintenance for the BOM

You can use the condition record maintenance for BOMs (transaction DVCO) to maintain receiver and sender condition records at the same time. A prerequisite is that both a sender and receiver search profile must be assigned to the derivation callup point in Customizing. The condition record maintenance on the BOM basis enables you to differentiate the attributes being transferred when you are using a material in different manufacturing BOMs. On the one hand, it may be necessary, for example, to transfer different attributes of the same sender for different BOMs when manufacturing a header material, while on the other hand you want to exclude the transfer of an attribute for this BOM item within this BOM.

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Steps for condition maintenance using BOMs: •

• •

•

Select the appropriate BOM alternative and usage for a derivation callup point and the header material. For the derivation callup points Release process/production order and Goods receipt for process/production order, you can derive onto a by-product or co-product. In the selection area, the header material of the BOM and all the components and there related characteristics are listed. To create the receiver and sender relationships, you select appropriate attributes in the attribute pool - meaning fields and characteristics, which you want to assign to the receiver and sender(s). You use drag and drop from the attribute area to transfer the attributes to the receivers and senders. From the tree structure of the selection area, you can double-click on the receiver material in the detail area to display the rules on which the derivation is based.

Derivation Monitor

Figure 197: Derivation Monitor

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Initial screen of the derivation monitor (1): You can use the derivation monitor to evaluate derivations on the basis of different criteria. •

• • •

You can enter the derivation monitor from the receiver material and its batches or from the sender material and its batches. You have the option of selecting derivations for batches after their expiry or manufacturing dates. You can also restrict the selection by choosing the derivation callup point, the creation date, or by entering the derivation number(s). You can use the derivation status to search for all the derivations in which errors or warnings occurred. You can save the criteria on which you want to base your search as variants.

Selection result in the derivation monitor (2): •

The selection result displays the header information for the derivation - the receiver material, the derivation number with the callup point and status of the derivation, the derived attributes, and information, warning and error messages.

When a derivation is performed for the first time, it can have one of the following three statuses: •

Derivation OK: The derivation was performed without any errors; performed with warning

You can manually confirm a non-validated derivation in the derivation monitor. Then the status changes: OK, data change, manually confirmed. Warning, (data change) manually confirmed. Error (data change) manually confirmed.

Batch Derivation: Summary You can use batch derivation to transfer, offer for selection, or display, batch master data and classification data from component batches that went into batches you produced.

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Lesson Summary You should now be able to: • Describe how you can use batch derivation to transfer values from batch attributes in the batch where-used list for component batches to batches of a finished product • Name the settings required in Customizing and in the application

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Unit Summary

Unit Summary You should now be able to: • Name the functions for realizing production in compliance with GMP • Give a definition for digital signatures and describe their functions and processing • Name the applications using digital signatures in the ECC System • Execute a digital signature • Find and display digital signatures • Define a signature strategy and describe how it is applied • Create approved process orders • Change approved process orders • Use the picking function to pack material components into handling units • Carry out a completeness check to identify the material components staged • Perform quantity reconciliation for the materials involved in the process • Outline the main steps that must be followed in master data maintenance to carry out an in-process quality inspection • Describe the functions of inspection lots and create an inspection lot for in-process quality inspection • Describe possible scenarios of an in-process quality inspection • Carry out in-process quality inspections with batch value assignment • Describe the structure and process of editing a batch record • Explain the status profile and version management for batch records • Explain how you can influence batch status management and the usage decision for an inspection lot • Describe how you can use batch derivation to transfer values from batch attributes in the batch where-used list for component batches to batches of a finished product • Name the settings required in Customizing and in the application

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Test Your Knowledge

Test Your Knowledge

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1.

Name the functions for realizing production in compliance with GMP.

2.

What does the digital signature do?

3.

How do you realize the use of approved process orders?

4.

What do the material identification functions do?

5.

How can the integration of batch management and quality management be used in relation to the value assignment to batches produced.

6.

What parts can the version of a batch record contain?


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7.

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What can you use the functions of batch derivation for?


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Test Your Knowledge

Answers 1.

Name the functions for realizing production in compliance with GMP. Answer: • • • • • •

Digital signature Approved master recipes and inspection plans Approved process orders Material identification and material reconciliation Integration with quality management Batch management – –

2.

Batch record Batch where-used list

What does the digital signature do? Answer: You can specify that a user must execute a digital signature to be able to carry out particular business transactions in the ECC System. The digital signature ensures that a user is uniquely identified and that the user name is documented together with the signed transaction, date, and time, and cannot be forged.

3.

How do you realize the use of approved process orders? Answer: You can specify that process orders of a specific order type have to be approved. A process order can be approved by selecting an approved recipe when creating the process order or by approving the order individually after it has been created.

4.

What do the material identification functions do? Answer: You can use the material identification functions to check the completeness and sequence of the material components staged.

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How can the integration of batch management and quality management be used in relation to the value assignment to batches produced. Answer: You can use the inspection results of quality management for batch value assignment by automatically copying them to the characteristics of the batch produced.

6.

What parts can the version of a batch record contain? Answer: At most, the batch record version can contain all of the following: • • •

• • • • 7.

One document for the table of contents and version data of the batch record One document in which the deviations that occurred during batch processing are listed Documents for the following ECC objects: All process orders to which the batch has been assigned, the material lists of these process orders, the PI sheets of the process orders, the process messages for the process orders, all inspection lots for the batch One document for user-defined data in which you can combine further ECC data according to your company's requirements One attachment with archive files from external systems, raw data from the process control system, or labels The comments entered for the version The digital signatures executed during approval

What can you use the functions of batch derivation for? Answer: You can use batch derivation to transfer, offer for selection, or display, batch master data and classification data from component batches that went into batches you produced.

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Unit 12 Appendix: Integration with Production Planning Unit Overview Topics: • •

• •

Overview of planning functions and planning elements (ECC and SCM(APO)) Planning and conversion of planned orders in the SAP ECC System - sample scenarios: – Multilevel MRP in ECC – Planning for make-to-order production in ECC SCM(APO) as a planning tool Planning and conversion of planned orders in the SAP SCM(APO) System – –

Individual conversion of planned order into process order Time-oriented collective conversion


Describe the options for production planning with SAP Explain how planned orders are created in the SAP ECC System, converted to process orders, and which functions are carried out for this Explain how planned orders are created in the SAP APO System and converted to process orders, and which functions are carried out.

Unit Contents Lesson: Overview of Planning Functions and Planning Elements .......768 Lesson: Planning and Conversion of Planned Orders in the SAP ECC System ...........................................................................771 Lesson: Planning and Conversion of Planned Orders in the SAP SCM(APO) System .............................................................787

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Lesson: Overview of Planning Functions and Planning Elements Lesson Overview This lesson provides you with an overview of SAP planning functions and elements.


Describe the options for production planning with SAP

Business Example You will get an overview of the planning levels preceding process manufacturing and of their functions and elements.

Cross-Application Process Flow (Recap.) Figure 198: Cross-Application Process Flow (Recap.)

Process order management represents a central part of a complex process chain ranging from a requirement (planned or customer requirement) through to the goods issue of finished products. Process order management controls the entire process of in-house production of products. Process order execution is, for example, integrated with the functions of capacity requirements planning, costing, and inventory management. In addition, there are links and interfaces to ECC Quality Management, external laboratory information systems (LIMS), and process control systems.

Overview of Planning Functions and Planning Elements Figure 199: Overview of Planning Functions and Planning Elements

SAP solutions offer two solution approaches to the integration of manufacturing and planning Planning with the functions of the component SAP SCM (APO)

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Lesson: Overview of Planning Functions and Planning Elements

Planning with the functions of the component SAP ECC Production preparation, execution, and control are always carried out using ECC functions. They are, however, dependent on the production type. Such functions are costing, release, material staging, confirmation, goods movements and settlement. For other functions (such as scheduling, availability check, machine commitment), you can choose between the two SAP components. The master and transaction data (planned orders, production and process orders, purchase requisitions, purchase orders, stocks, ...) are usually exchanged (mirrored) between the two SAP components through the “Core Interface” (CIF). Specific events lead to the transfer of data from ECC to SCM (APO) (release, confirmation, goods receipt) and vice versa. Sales orders are generally entered in ECC and then transferred to SCM (APO). Planned orders can be created by material requirements planning (MRP) in ECC or in SCM with •

Supply Network Planning (SNP) in APO. This allows for cross-plant planning in a long-term time horizon across the entire supply and procurement chain. Here, purchase requisitions of stock transfers (distribution), planned orders (in-house production) and purchase requisitions (external procurement) are created for the relevant production plant.

•

Production planning and detailed scheduling in APO (PP). This creates planned orders and purchase requisitions in a defined, short-term period (production horizon) in the production plant.

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Lesson Summary You should now be able to: • Describe the options for production planning with SAP

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Lesson: Planning and Conversion of Planned Orders in the SAP ECC System

Lesson: Planning and Conversion of Planned Orders in the SAP ECC System Lesson Overview This lesson informs you about the planning and conversion of planned orders in the SAP ECC System using two example scenarios. • •

Multi-level MRP Planning with Make-to-Order Production


Explain how planned orders are created in the SAP ECC System, converted to process orders, and which functions are carried out for this

Business Example You will first get an overview of MRP operations in the SAP ECC System.

Sample Scenario 1: Multi-level MRP in ECC

Figure 200: Sample Scenario 1: Multi-level MRP in ECC

Your company produces packaged Cetepharm tablets:

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For the Cetepharm tablet production, your company first manufactures acetylsalicylic acid. Together with other ingredients, it is used as the active ingredient for the Cetepharm tablet production. The tablets are packaged into various sizes and quantities.

Planning Strategy

Figure 201: Planning Strategy

A planning strategy represents business procedures for planning production quantities and dates using sales orders and planned independent requirements. The components ECC and SCM(APO) support various planning strategies. To plan the production of the packaged Cetepharm-N tablets, your company chooses the planning strategy “Planning with final assembly”. Reasons for using this planning strategy: • • •

A planned independent requirement drives the manufacturing process. If the sales orders are not covered by the planned independent requirements, they are adjusted and in this way the demand program as well. In this way, manufacturers can quickly react to sales orders.

The Cetepharm-N packaged tablets have a multi-level BOM structure. The production takes place in 3 stages.

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Multi-level MRP

Figure 202: Multi-level MRP

MRP analyzes the demand from sales orders and planned independent requirements. If stock and the planned receipts are not enough to cover the demand, a planned order is created. It consists of a suggested order quantity, a start date, and a finish date. By exploding the bill of material of the planned order, dependent requirements are created, for which, in turn, the requirements situation is analyzed. If there is a shortage, a planned order is created to cover the relevant dependent requirements. In this way, multi-level planning plans a complete BOM structure. The following steps are carried out per material for MRP across the entire product structure:

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• • •

Checking requirement coverage Creating a planned order Determining dependent requirements

•

Entering the component in the planning file


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Stock/Requirements List and MRP List

Figure 203: Stock/Requirements List and MRP List

You can evaluate the planning situation or the result of a planning run using the stock/requirements list or MRP list in the SAP ECC System. You can use individual or collective access for this. The MRP list represents the result of the last planning run and therefore has a static nature. • • • • •

Changes that were made after the planning run are not visible. You can control whether an MRP list is to be created during the planning run. The MRP list is divided into different planning segments. Changes between two planning runs are not displayed. Error messages are stored in a log.

The stock/requirements list is a dynamic list created by directly reading the MRP elements. Therefore, it always shows the current stock/requirements situation (stocks, requirements, and receipts). •

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The two lists have the same basic structure: • • •

The MRP controller’s worklist is displayed to the left in the form of a tree (optional). Above the list, there is the header with the material number and material master details. The list contains the individual MRP elements and the corresponding available quantities.

User-specific settings enable you to tailor the lists according to your own personal needs. You can convert individual planned orders to process orders from this list.

Structure of Planned Orders (ECC)

Figure 204: Structure of Planned Orders (ECC)

The planned requirements quantity and date of availability are defined in the planned order header. The component overview of the planned order provides information about the planned material components (dependent requirements). If the planned order was scheduled via the recipe, it also contains the capacity and scheduling data.

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In summary, a planned order represents: • • • •

The planned receipt of net requirements calculation to cover the requirements The source of the requirement of the dependent requirements Possibly, a pegged requirement for capacity requirements planning The data source for the process order

Scheduling in Production Planning (ECC)

Figure 205: Scheduling in Production Planning (ECC)

Production planning knows two scheduling methods that are used for different purposes and have different results: • •

Planned order scheduling in MRP (only calculates basic dates) Lead time scheduling (calculates production dates based on basic dates). Only lead time scheduling calculates operation-related dates and capacity requirements.

Lead time scheduling is used for: • • •

Order scheduling (process order, production order) Recipe/routing scheduling Scheduling in PS and PM

(*) To determine capacity requirements for planned orders you can also switch on lead time scheduling in MRP.

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Planned Order Dates (ECC)

Figure 206: Planned Order Dates (ECC)

Planned orders have an order start date (OS), an order finish date (OF), and a planned opening date (PO). The planned opening date is the date on which a planned order should be converted into a purchase requisition or process order. It is used as a selection criterion for the collective conversion. The lead time between the opening date and the order start date is to allow sufficient time for carrying out certain administrative steps that may be required.

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Planned Order Conversion (ECC)

Figure 207: Planned Order Conversion (ECC)

The MRP controller uses collective conversion to convert the planned orders of a product structure one after another along the time axis. Within the entire product structure, only those planned orders are offered for conversion whose planned opening dates are within an opening period to be defined. The system determines whether in-house production or external procurement is required using the procurement type and other control elements (for example, special procurement key) defined in the material master record. You can specify that collective conversion depends on the result of the material availability check (in the same way as order release).

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Order Creation with Planned Orders

Figure 208: Order Creation with Planned Orders

Planned orders are created in material requirements planning (ECC - MRP) or in planning in SCM(APO) (APO - PP/DS or APO - SNP). The process order data is provided automatically through the conversion of planned orders. Inspection data is copied from the master recipe when an inspection lot is generated, but not written in the process order. MRP controllers (buyers) can convert planned orders generated in planning (and purchase requisitions to purchase orders) both in SAP(APO) and in SAP ECC.

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Conversion of Planned Orders to Process Orders (ECC)

Figure 209: Conversion of Planned Orders to Process Orders (ECC)

Planned orders can be converted completely or partially in individual or collective conversion in dialog mode. By converting a planned order to a process order, the planned order is deleted. The dependent requirements (material components) and capacity requirements that may exist are reallocated to the new process order. By changing an indicator, the dependent requirements are turned into a reservation. In partial conversion, the planned order still exists and is fixed.

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Reservation

Figure 210: Reservation

Material reservations are created for all material components of type Stock material of a process order. Reservations are taken into account in requirements determination of MRP. A reservation item is valid for a plant or storage location of a plant. When you create a process order, the dependent requirements are converted to reservations during planned order conversion. When you manually create an order, the system reads the BOM for the material. For the order, the system creates a reservation for the required material components. In the process order, the reservation items are displayed in the form of the material list. The reservation items are contained in the corresponding stock/requirements lists as MRP elements. Material withdrawals for the order are carried out with reference to the reservation assigned. The requirements quantities of the reservation are reduced when the corresponding materials are withdrawn. The reservations for the material components of the process order are assigned to the process order account. Lists of reservations for the material or account assignment (process order) can be created.

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Sample Scenario 2: Make-to-Order Production in ECC

Figure 211: Sample Scenario 2: Make-to-Order Production in ECC

Your company is a specialized chemical manufacturer. Most of the products are specially formulated for customers. One of your customers is a garden products distributor called Specialty Garden Products who sells a special formulation fertilizer. This customers orders the fertilizer sporadically, depending on the season and weather conditions. The fertilizer has high production costs. In addition, it has a relatively short shelf life. Specialty Garden Products is the only customer that orders this product. The Make-to-order planning strategy is used to support the planning of the special formulation liquid fertilizer.

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Make-to-Order Production

Figure 212: Make-to-Order Production

In a make-to-order environment, the sales order drives the production and procurement processes. In addition, there are other variants of the make-to-order strategy which allow, for example, certain levels in the BOM structure to be planned and produced using planned independent requirements. This is done to deliver products within a reasonable time after a sales order is entered.

Make-to-Order Production: Key Material Master Settings

Figure 213: Make-to-Order Production: Key Material Master Settings

Strategy group 20: The strategy group is used to assign a planning strategy or a group of planning strategies to a material. The planning strategy represents the procedure used for planning and manufacturing a material. Individual/collective requirement:

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This indicator controls whether or not individual customer requirements planning (make-to-order production) is used for dependent requirements.

MRP in a Make-to-Order Environment (I)

Figure 214: MRP in a Make-to-Order Environment (I)

For each component with individual requirements, the system creates a separate planned order with lot-for-lot order quantity for the individual customer stock of the sales order. Planned orders created for different sales orders cannot be grouped together.

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MRP in a Make-to-Order Environment (II)

Figure 215: MRP in a Make-to-Order Environment (II)

Assume you are using the make-to-order production strategy for material X, you have entered two sales orders, and MRP has been run. The stock/requirements list shows two individual customer segments, one for each sales order. Suppose you want one or more components in the bill of material to be produced or procured for the same sales order. You use the Individual/Collective indicator to specify this. You can find this indicator in the MRP4 view of the material master. If you enter 1, this indicates individual requirements. This means that the component is being produced or procured for the same requirement. A separate segment is created for each requirement. In the example, two sales order stock segments are maintained for material Y. If you enter 2, this indicates collective requirements. This means that the component is being produced or procured for several requirements (that is, not for any specific requirement). In the example, material Z is planned using a static lot-sizing procedure (exact lot size). The 5 units in stock and the requirements are balanced against each other. No individual customer segments are created. If you do not make an entry, this indicates that the component is planned in the same way as the product.

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Lesson Summary You should now be able to: • Explain how planned orders are created in the SAP ECC System, converted to process orders, and which functions are carried out for this

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Lesson: Planning and Conversion of Planned Orders in the SAP SCM(APO) System

Lesson: Planning and Conversion of Planned Orders in the SAP SCM(APO) System Lesson Overview This lesson informs you about the planning and conversion of planned orders in the SAP SCM(APO) System.


Explain how planned orders are created in the SAP APO System and converted to process orders, and which functions are carried out.

Business Example You will first get an overview of MRP operations in the SAP SCM(APO) system.

SCM(APO) as a Planning Tool

Figure 216: SCM(APO) as a Planning Tool

Instead of using SAP ECC MRP for material requirements planning, you can also use SAP SCM APO PP/DS.

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SAP SCM (APO) is a planning tool. SAP SCM (APO) enables integrated, global representation, planning, and monitoring of all processes in the logistics chain in detail. Open standard interfaces enable a smooth integration of SAP Systems, highly-integrated solution for ECC, legacy systems, and systems from other suppliers. SAP SCM(APO) is highly efficient with liveCache, an SAP technology for memory-resident data processing. Inventory management, sales order entry, and order execution and control (Manufacturing Execution) take place outside SCM(APO), for example, in the ECC System. SAP SCM(APO) can be used to generate and change orders (planned, production, or process orders), as the result of a planning run. The link between SCM(APO) and ECC can be obtained using Core Interface (CIF). The data is stored on both sides (SCM(APO) und ECC).

Master Data for Planning and Production

Figure 217: Master Data for Planning and Production

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Specific business operations for planning and shop floor control in ECC and in SCM (APO) are based on master data from Lifecycle Data Management. Lifecycle data management is a key functional area in the mySAP Product Lifecycle Management (PLM) solution. The master data objects from ECC and SCM(APO) are not identical. The ECC System is the leading system for the master data. The Core Interface (CIF) allows the relevant ECC master data to be mapped onto the corresponding master data in SCM(APO). Both the initial transfer of data as well as the supply of changes made to data (change transfer) in SCM(APO) are achieved via the CIF. The master data transferred from ECC and SCM(APO) is defined in an integration model in ECC.

Figure 218: Transaction Data for Planning and Production

The transaction data transferred from ECC and SCM(APO) is defined in an integration model in ECC. All ECC transaction data is represented in SCM(APO) by orders, which are distinguished using their ATP category.

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Benefits of Detailed Production Planning in SCM(APO) • • • • • • • •

Detailed scheduling with simultaneous quantity and capacity planning (PP/DS) Material requirements planning to the time (hours, minutes), also for dependent requirements Multi-level availability check of materials and capacities (ATP) for sales orders Multi-level forward scheduling (pegging) Optimization algorithms during detailed scheduling (minimization of setup times, setup costs, delays, alternative resource selection, ...) Campaign planning Dynamic exception messages (alerts) Capacity categories: time, activity, volume, piece

Product View

Figure 219: Product View

The product view is a dynamic list that shows the current stock/requirements situation (planning situation for a specific product in a location). It thus is a versatile and flexible tool with which you can carry out a range of functions. Interactive planning can be carried out in the change mode. Individual planned orders can be converted to process orders. You can display and changeMRP elements.

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After you save the results, the new, up-to-date situation is shown. It is possible to explicitly refresh the list if you want to display the current planning status again. Exceptional situations (alerts) are displayed dynamically and you can always navigate to the Alert Monitor. The basic structure of the product view contains a header with the product number at the top, an optional overview tree to the left, and the lists with the individual MRP elements and the quantities available at the bottom of the screen. Further tab pages contain additional information. You can personalize the display.

Planned Order Conversion in SCM(APO)

Figure 220: Planned Order Conversion in SCM(APO)

APO planned orders contain all production dates and dispatched, scheduled operations. APO planned orders can be transferred to ECC. The ECC planned orders resulting from this do not contain production dates nor capacity requirements. They only contain the basic dates and dependent requirements for all components (no matter whether they are APO-relevant or not). Based on these dependent requirements, all components are planned (in SCM(APO) or ECC).

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APO planned orders should always be converted in SAP SCM(APO). If you set the conversion indicator in the APO planned order, a process order is created in ECC. This order takes on the production and operation dates determined in SCM(APO). The APO Core Interface assigns the order number of the process order created in ECC to the APO planned orderso that the APO planned order then appears as an APO process order.

Conversion of Planned Orders to Process Orders SCM(APO)

Figure 221: Conversion of Planned Orders to Process Orders SCM(APO)

APO planned orders can be converted in dialog mode in individual or collective conversion. To convert a single planned order to a process order, you only set an indicator in the product view. The order continues to exist in SAP SCM(APO). Order and operation dates are taken over to the ECC process order. By changing an indicator, the dependent requirements are turned into a reservation. Partial conversion was not implemented.

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Lesson Summary You should now be able to: • Explain how planned orders are created in the SAP APO System and converted to process orders, and which functions are carried out.

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Unit Summary

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Unit Summary You should now be able to: • Describe the options for production planning with SAP • Explain how planned orders are created in the SAP ECC System, converted to process orders, and which functions are carried out for this • Explain how planned orders are created in the SAP APO System and converted to process orders, and which functions are carried out.

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Test Your Knowledge

Test Your Knowledge

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1.

Name the two options for integrating manufacturing and planning.

2.

How can you evaluate the result of a planning run in the ECC System?

3.

Where can the planning results be evaluated in the SAP SCM(APO) System?


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Answers 1.

Name the two options for integrating manufacturing and planning. Answer: •

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

•

2.

Production preparation, execution, and control are always carried out using ECC functions. They are, however, dependent on the production type.

How can you evaluate the result of a planning run in the ECC System? Answer: You can evaluate the planning situation or the result of a planning run using the stock/requirements list or MRP list in the ECC System.

3.

Where can the planning results be evaluated in the SAP SCM(APO) System? Answer: You can evaluate the planning situation by using the product view in the SAP SCM(APO)System.

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Course Summary

Course Summary You should now be able to: • • • • • •

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Explain where process orders fit in within the Supply Chain Management Carry out the individual steps of process order management Use the main order management functions Make important system settings Take integration relationships into account Learn about further special functions by studying on your own


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Course Summary

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Feedback SAP AG has made every effort in the preparation of this course to ensure the accuracy and completeness of the materials. If you have any corrections or suggestions for improvement, please record them in the appropriate place in the course evaluation.

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Scm340 en Col52 Fv Part a4

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