SAP_pp.pdf

Training Manual

SAP PP

TechVantage IT Solutions Pvt Ltd

SAP PP ( Master Data ) Define Bill Of Material : I ) It is a complete formally structured list of the components that make up a product

II) THE LIST CONTAINS ; CONTAINS ; a ) A Description Description , b ) Object number for each component , c ) Together with the quantity , d ) Unit of Measure .

The BOM in the following Area; a ) MRP explodes MRP explodes BOMs to Determine Economical order Quantities at a particular point in

time.

b) Work scheduling makes scheduling makes BOMs the basis for planning operation and shop floor control . c ) The departments responsible departments responsible for i ) handling handling reservations , ii ) Good Good issues , iii ) sales order use BOMs as an aid to enter an Data , d ) Product costing uses costing uses BOMs To calculate material usage cost for a Product

BOM Categories: A ) Material BOM

T Code - CS01

B ) Order BOM

T code - CS61

C ) Document Structure

T code - CS11

D ) Equipment BOM

T Code - IB01

E ) Functional Location BOM

T code - IB11

A) Material BOM; It represents the structure of the Manufactured Product in SCM. B) Order BOM; It produces a product for a Specific Sales Order C) Document Structure; a) It consists of several documents such as , 1. A program,

2. Technical Drawings,

3. Paper Documents,

4. Photographs.

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b) You need to create Document information records for these Documents. D) Equipment BOM; It is used in plant maintenance to describe the structure of a piece of equipment F) Functional Location BOM; It is used in plant maintenance to link equipment to specific locations.

BOM Usage: It allows you to create separate BOMs for various areas within the company. Examples of BOM usage: A)

Engineering BOM

B)

Production BOM

C)

Costing BOM

A) Engineering BOM; It is the combination of all the components of the products from an Engineering perspective. It contains all the Technical Data. B) Production BOM; It is set from a Manufacturing Perspective. E.g. process Data is required for assembly Purposes C) Costing BOM: It is for automatically calculating the material usage and cost of a Product


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Creation of Bill Of material; (CS01) Step I Create Material BOM

1.

Enter T-code CS01 in the command field. ( SAP Easy access Screen )

2.

Enter Material / Plant / BOM usage .

Enter Item Code, Material component and Quantity.

Step-3 Click on save button. A Message as


will be displayed.

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Configuration of Bill OF Material : In customizing Choose , Production ↓ BASIC DATA ↓ BOM ↓ CONTROL DATA FOR BOM ↓ DEFINE MODIFICATION PARAMETERS

On the change view „” Modification parameter For BOMs : Details Screen Select the Low date check box under validity


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Press F1

The Above screen Appears.

In the technical type Screen Area Select the Multilevel BOM inactive checkbox :

In customizing Choose, Production ↓ BASIC DATA ↓ BOM ↓ CONTROL DATA FOR BOM ↓ DEFINE MODIFICATION PARAMETERS

On the change view “modification parameters “modification parameters for BOMs


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Details screen select the multilevel BOM inactive Checkbox under Technical type

Press F1 The above Screen appears


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WORK CENTER; A WORK CENTER IS A LOCATION WHERE A PERTICULAR OPERATION IS EXECUTED.

EXAMPLES; THE FOLLOWING CAN BE DEFINED AS A WORK CENTER A ) INDIVIDUAL WORK CENTER B ) STATISTICAL WORK CENTER C ) PRODUCTION LINE

WORK CENTER CREATION; (T CODE CR01) STEP I)


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b ) ENTER THE FOLLOWING DATA ; FIELD PLANT WORK CENTER WORK CENTER CATEGORY


VALUE 1000 CENTER 07 0003

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On The Basic Data Page Enter The Following Data; Field

value

Description Person responsible Usage Standard value key

Pump assembly 007 009 ( all task list types ) sap1 (Normal production )

Rules for maintenance

set up – should be entered Matchine -- must be entered Labour --- no checking


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I ) on the Default value tab page choose the control key (Between pp01 and pp99 ) II ) minutes as the unit of measure. III ) Select the ref . Ind. Checkbox for the control key.

Now save your Entries …………………. Work CENTER center007 IN PLANT 1000 WAS CREATED …. THE ABOVE MSG YOU WILL GET WHEN ALL THE ENTRIES SAVED IN THE SYSTEM….


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1) Scheduling

When a production order is created, the duration of an operation can be calculated based on operating times in routing and formulas which are entered in the Work Centre.

2) Costing

The costs of an operation can be calculated in the production Order based on the formulas which are entered in the Work Centre. Work Centre is also linked to a cost centre.

3 ) Capacity Planning

The available capacity and formulas for calculating capacity requirements are stored in the Work Center.



Work Centres are used in routing operation data.



Work Centre is created for a manufacturing plant and is identified by a code.



Group of similar machines can also be created as a single Work Centre. For example, 5 similar machines can be created as 1 Work Centre with a number of capacities as 5.


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How to create Work Centre

Step I ) 1) From SAP Easy access open TRANSACTION CODE CR01 Enter your manufacturing Plant code where Work Centre needs to be created. Enter Work Centre code. Enter the Work Centre category as "0001" which means Work Centre would be categorized as machines.

After filling in all the fields, click


or press Enter to go to the next screen.

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Step 2) In this Screen, Work Centre basic data would be entered as given below. Input Work Centre description. Enter person responsible code for that Work Centre. Enter physical location where Work Centre is located in the plant. Enter usage as "009" which means Work Centre is valid for all task list types such as production routing, maintenance task list, etc. Enter standard Value key which contains different activity types used for standard cost calculation.

Step 3) In this Screen under "Capacities Tab." Enter Capacity category as "001" which represents machine category. Input processing formula as "SAP006" - It is used to calculate the available capacity of Work Centre. SAP006 =( Operation quantity* machine time )/ base quantity After filling in the capacity category and processing formula, click on the


button:

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It will open another screen.


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Step 4) In this Screen under capacities Tab, capacity data will be entered. Enter Capacity description. Enter details about "Input capacity planner group", which is responsible for machine capacity. Enter factory calendar ID, which has public holidays listed for your plant. So, on holidays, capacity for that Work Center would be zero. Input base unit of measure as "MIN" which means work centre available capacity will be measured in time i.e. min. Enter the time period (start and finish time) for which Work Centre would be available for operation. Enter capacity utilization percentage %( how much time it is utilized out of the standard available working time) of the Work Centre considering the breakdown and preventi ve maintenance of the machine. Input number of capacities which means a number of similar Work Centre. Check "relevant for finite scheduling and "long term planning" flags which indicate if there is a capacity constraint, then the operation is moved to a certain date where it can be processed without capacity constraints.


to go back to the Work Center capacity overview.

Then click on the tab "Scheduling" tab from the menu, the system will show the following screen: Step 5) In Scheduling Tab,


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Enter Capacity category as "001" which represents machine category and hence machine time would be the basis for calculating schedule time in production order. Input processing formula as "SAP002" which is used to calculate scheduling time. SAP002 = (Operation quantity* machine time)/ base quantity/no. of splits.

After filling in all the fields, click on the tab "Costing." Step 6) In Costing Tab Enter Start and Finish date which represents validity date of the cost centre. centre. Input cost centre to centre to which operational costs would be booked. Input all activity types along with the formulae, which would be used for calculating the activity costs.


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Click button

SAP PP


to save the new Work Center. The system will show

message


at the lower left corner.

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CREATING CAPACITIES IN THE WORK CENTER A ) POOLED CAPACITY b ) REFERENCE CAPACITY

POOLED CAPACITY; 1 ) A pooled capacity can be assigned to several work centers. 2 ) It is created and e dited independently of the work center. 3)This is useful if, for instance, a group of employees works in several work centers.

Reference Capacity: 1) A reference capacity is used used to simplify the maintenance of work center capacities. 2 ) It is used to copy or reference an available capacity from. 3 ) Reference capacities are created and maintained maintained separately from work centers.


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Routing;

Definition A routing is a description of which operations (process steps) have to be carried out and in which order to produce a material (product). As well as information about the operations and the order in which they are carried out, a routing also contains details about the work centres at which they are carried out as well as about the required production resources and tools (includes jigs and fixtures). Standard values for the execution of individual operations are also saved in routings. Routings (generic) consist of the following objects:



Routing



Rate routing



Reference operation set



Reference rate routing

Use : A routing is used as a source for creating a production order or or a run schedule header by copying.

Structure

1) A routing is composed of of a header header and one or more sequences. 2) The header contains data that that is valid valid for the whole routing. routing. 3) A sequence is a series of operations. 4) Operations describe describe individual individual process steps, which are carried out during production (see (see routing graphic) 5) A routing routing is identified by its group and group counter.


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Routing

Integration:

Group and Group counter A )

Routings within a group are distinguished by their group counter.

B)

In the graphic the three routings in group A are identified by their group counter


1,2 or 3.

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Group


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Step 1) From SAP Easy access menu, open Transaction code CA01

1.

Enter parent parent material for which routing needs to be created.

2.

Enter Plant Code.

3.

Enter the Key date (valid from date) which means means that routing would be valid from that date.


or press Enter to go to the next screen.

"Header Details"


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Step 2) In this step, we will maintain routing header data as given below.

1.

Enter Usage as "1" which is meant for Production routing and will be used in Production Order. There There are other task list usages which are meant for Plant maintenance and inspection plan.

2.

Enter Status as "4" which is a released status. It indicates that routing is valid for material material requirement planning and costing.

3.

Enter Lot Size as "99999999" "99999999" which means that routing is valid for order order quantity between 0 and 99999999.

4.

Press Operation button to add the sequence of operation and follow next step 3.

Some information such as Description, Group Counter and Basic Unit Measure will be populated by system automatically.

Click Operation tab and it will open "Operation Overview" screen.

Step 3)


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In this step, we will maintain operation data.

1.

Enter Work Centre code at which operation is carried out.

2.

Input Control Key which determines determines whether operation should be scheduled, costed and if auto goods receipt is possible while doing production confirmation. It is generally configured depends upon your business process.

3.

Input the operation description.

4.

Input the base quantity or output quantity quantity of the material material which indicates how much quantity of material would be produced in machine and labour time mentioned at point no. 5 & 6.

5.

Enter set up time time in minutes required for the base quantity. quantity.

6.

Enter Machine Machine time in minutes required for the base quantity. quantity.

Click

to save the new routing, system will show

message


at the lower left corner.

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How to Change Routing We would change routing if we have replaced old with new work centres centres or or added one more operation to our manufacturing process. If our machine productivity is increased then we need to change the machine time or base quantity. Step 1) From SAP Easy access menu, open Transaction CA02

1.

Enter parent parent material for which routing needs to be changed.

2.

Enter Plant Code.

3.

Key date (valid (valid from date) which means that routing would be valid from that date is set to current date automatically.


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Step 2) After filling in all the fields, click (ri click (right ght mar mark k sign) sign)

1.

from the top men menu u to go to to the the next next scree screen. n.

Change the control key from PP01 (without auto GR indicator) to PP03 (Auto GR indicator).Auto Goods Receipt means means when you do production confirmation, Goods receipt of material will happen automatically.

2.

Change the Machine time.

After finishing all modifications, click


to save Routing.

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How to display Routing To display the routing we will follow the following steps. Step 1) From SAP Easy access screen open in transaction CA03

1.

Enter parent material material for which routing needs to to be displayed.

2.

Enter Plant Code.

3.

Key date (valid (valid from date) which means that routing would be valid valid from that date is set to current date automatically.



sign from top menu to go to the next screen and display the routing.

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Step 2) In 2) In this screen we will see, how the operation data of routing is displayed.

1.

The screen will display the operation data of routing like – operation carried out by the w ork center, base quantity (100 EA), set up time (10 minutes) and machine time (35 minutes.)

Troubleshooting



There might be the case wherein material master record does not exist. For this, you need to create the material master for the material before creating routing.



Some users might get error "work centre centre does does not exist". In this case, work centre centre should should be created beforehand.


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