step-by-step-sap-pp-user-manual.pdf

Organization Project

Sujan Barre Thomas Anti-Vibration Systems Pvt. Ltd., Thane “VISION”

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Production Planning (PP)

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END USER MANUAL SAP, PRODUCTION PLANNING (PP) MODULE

PROJECT

“VISION” SUJAN BARRE THOMAS ANTIVIBRATION SYSTEMS PVT. LTD., Thane

Prepared By, HARRIS PANCHAL SAP Consultant, PP Mahindra IT Consulting Pvt. Ltd., Mumbai

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DOCUMENT CONTROL

Sr. No.

Revision

Date of Creation

Date of Modification

Remarks

1

1.0

07-February-09

07-February-09

---

Security Classification: COMPANY CONFIDENTIAL

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Contents 1. CHECK SCHEDULING AGREEMENT – MD04....................................................................................4 2. CHECK STOCK OF MATERIAL - MMBE.............................................................................................6 3. EXPLODED BOM VIEW – CS11 ..........................................................................................................9 4. RESERVATION CREATION ...............................................................................................................11 4.1a BY MANUAL CREATION THROUGH – MB21...................................................................11 4.1b RESERVATION DISPLAY – PRINT FOR INTIMATION – MB25 .......................................14 4.1c STOCK TRANSFER POSTING – MB26 ............................................................................18 4.2 BY MANUAL CREATION THROUGH – MB1B ....................................................................19 5. CHECK BILL OF MATERIAL – CS03 ................................................................................................21 5.1 CHECKING STANDARD BOM.............................................................................................21 5.2 ADDING AN ALTERNATIVE BOM .......................................................................................23 6. CHECK ROUTING – CA03 .................................................................................................................25 6.1 CHECKING STANDARD ROUTING ....................................................................................25 6.2 ADDING AN ALTERNATIVE ROUTING ..............................................................................28 7. PRODUCTION ORDER CREATION – MANUAL – CO01..................................................................30 8. SHOP FLOOR PRINTING – PRODUCTION ORDER – CO04 ...........................................................35 9. PRODUCTION ORDER CONFIRMATION – CO11n ..........................................................................39 10. QUALITY INSPECTION – QA32.......................................................................................................43 11. PRODUCTION ORDER SETTLEMENT – KO88 ..............................................................................51 12. PRODUCTION ORDER TECO – (Technically Complete) – CO02 ................................................53 13. CHECK PRODUCTION ORDER REPORTS ....................................................................................55 13.1 PRODUCTION ORDER INFORMATION SYSTEM - COOIS ............................................56 13.2 CAPACITY PLANNING - STANDARD OVERVIEW – CM01 ............................................61 13.3 CAPACITY PLANNING - CAPACITY EVALUATION – CM50 ..........................................63 13.4 ORDER PROGRESS REPORT – CO46 ............................................................................66 13.5 DISPLAYING PRODUCTION ORDER CONFIRMATION – CO14 ....................................68 13.6 CHECK PRODUCTION ORDER DELIVERY – MB51........................................................69 13.7 CHECK RAW MATERIAL ISSUE – MB51 .........................................................................71 13.8 CHECK RAW MATERIAL RECEIPT – MB51.....................................................................73 13.9 MATERIAL USAGE ANALYSIS - MCRE............................................................................75 13.10 ANALYZE PRODUCTION ORDER – KKBC_ORD ..........................................................77 13.11 CHECKING FAILED GOODS MOVEMENT - COGI ........................................................79 14. PRODUCTION ORDER – THROUGH DEMAND MANAGEMENT ..................................................80 14.1 CREATE PLANNED INDEPENDENT REQUIREMENT – MD61.......................................80 14.2 MRP – AT PLANT LEVEL – MD01.....................................................................................83 14.3 MRP – AT MATERIAL LEVEL – MD02 ..............................................................................85 14.4 PRODUCTION ORDER CONFN. WITH REWORK – CO11n............................................93 14.5 PRODUCTION ORDER CREATION – REWORK – CO07 ................................................97 14.6 REWORK PRODUCTION ORDER CONFIRMATION – CO11n ......................................101 14.7 GOODS RECEIPT OF REWORK ORDER – MB31 .........................................................104 15. MRP – FOR PLANNED ORDER + PURCHASE REQUISITION....................................................107 16. CO-PRODUCT SCENARIO ............................................................................................................114

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1. CHECK SCHEDULING AGREEMENT – MD04 Sales & Distribution (SD) Module would be inputting Scheduling Agreement in the SD Module which would be visible in the Stock Requirement List (Dynamic Listing).

SAP ECC menu

Logistics → Production → MRP → Planning → Evaluations → Stock/Requirements List

Transaction code

MD04

Here enter the Material and the Plant who’s Requirements are to be checked.

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Here you can see the Scheduling Agreement inputted by SD.

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2. CHECK STOCK OF MATERIAL - MMBE The Stock of the Raw Material is checked against the Selection criteria.

SAP ECC menu

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

Transaction code

MMBE

Double click on the Transaction code and give the selection condition as per your requirement.

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Click on Execute

The System will Show you the Stock as of that particular Item. The system will show you the Actual stock lying at different areas such as Unrestricted, Quality Inspection, Reserved and Blocked Stock etc.

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If the stock is not available at IS01 (Issuing In-Between Storage Location), then, In-House Stock transfer of components has to be done, i.e. ST01 to IS01. Production Order will be consuming the Stock from ST01 (General Storage Location) to IS01 (In-between / WIP Storage Location). Also if the production department has determined the total quantity required for a particular material, say ROH, then they can check the same by exploding the total BOM Quantity.

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3. EXPLODED BOM VIEW – CS11 To check the Total Raw Material requirement by means of Exploding the Total BOM of a particular Material.

SAP ECC menu

Logistics → Production → Master Data → Bills of Material → Reporting → BOM Explosion→ Material BOM

Transaction code

CS11

Enter Material / Plant / Required Qty. / BOM Application and click on Execute

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After the execution, it will show the Total Requirement for that Finish Product in terms of Raw Material requirement.

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4. RESERVATION CREATION 4.1a BY MANUAL CREATION THROUGH – MB21 Now known the total quantity the Reservation needs to be created for the total requirement which was being put at the time of exploding the BOM.

SAP ECC menu

Logistics → Material Management → Inventory Management → Reservation → Create

Transaction code

MB21

Enter Movement No.: 311 for Plant 1000.

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Enter Material, its Quantity, Unit oF Measure, the Receving Storage Location (IS01) and Storage Location (ST01)

And Click on SAVE. Reservation is created and it will be shown with a Green Tick and a Reservation No. being created.

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Note the Reservation No. shown in the System Status bar.

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4.1b RESERVATION DISPLAY – PRINT FOR INTIMATION – MB25 SAP ECC menu

Logistics → Material Management → Inventory Management → Reservation → Reservation List

Transaction code

MB25

Enter Material & Plant 1000.

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Click on Execute

Reservation List Display will be seen. Select the Reservation Line and Click on Change Layout From Drop Down menu

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Select Choose to select the saved Layout.

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Now you can see the details as per the selected Layout.

Select this line and Click on Print Option. Once the Spool is created, go to Spool Management to select the print to be printed as a Hard Copy which then can be given to the Stores for issuing the material from ST01 to IS01.

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4.1c STOCK TRANSFER POSTING – MB26 SAP ECC menu

Logistics → Material Management → Inventory Management → Reservation → Picking

Transaction code

MB26

You can enter here the Material / Reservation No. / Order No. / Plant as per your filtering requirement. After entering you can simply select the One Reservation which you want to post, multiple selection is also possible. If only 1 is to be posted then you need to delete the other postings and then Post the one which was kept. Goods movement would take place, which would mention it by Displaying a Green Tick mark in the status bar. Now the required material is available at IS01.

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4.2 BY MANUAL CREATION THROUGH – MB1B SAP ECC menu

Logistics → Logistics Execution → Internal Whse Processes → Posting Change → Inventory Management→ Enter Posting Change

Transaction code

MB1B

Here with this TCode you can directly post the required stock within plant.

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Enter the following details on the main Screen viz. 1. Movement Type: 311 2. Plant: 1000 3. Storage Location (Where the goods exists, Transfer from location): ST01 On the next screen Enter the following: 1. Rcvg SLoc (Where the material is needed to consume): IS01 2. Enter the Material details and Storage Location

And SAVE to post the material to the required Storage location.

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5. CHECK BILL OF MATERIAL – CS03 5.1 CHECKING STANDARD BOM SAP ECC menu

Logistics → Production → Master Data → Bills OF Material → Material BOM → Display

Transaction code

CS03

Now enter the Material number of which you BOM you want to see and execute.

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System will show you the Bill Of Material with details like material included in bill of material, description of the component, quantity required with unit of measure.

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5.2 ADDING AN ALTERNATIVE BOM SAP ECC menu

Logistics → Production → Master Data → Bills OF Material → Material BOM → Create

Transaction code

CS01

At times there are chances that an Alternative Material is available to produce a particular component. In that case an Alternative BOM for the same FERT would be required. To do so, CS01 can be used to create an Alternate over an Existing BOM.

It would highlight that an Alternative 2 added to BOM and a New Page for entering the BOM components would come where you can enter the new / alternate components.

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Other relevant details such as Storage Location and SAVE the BOM. Once you have created it and when you open the BOM in change mode it would show you 2 alternatives and you can select which one you want to view / modify.

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6. CHECK ROUTING – CA03 6.1 CHECKING STANDARD ROUTING SAP ECC menu

Logistics → Production → Master Data → Routings → Standard Routings → Display

Transaction code

CA03

Enter the Material Number & Plant to display the Routing.

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System will display the routing of the material with details such as work center used operation performed, Base quantity and the Activities. If the Group No. is already visible in the field, remove the same and give Enter.

A Production Resource Tool (PRT) i.e. in case of SBT it is a Mould can be checked. In the above view th

9 Column shows the TICK MARK which is grayed for PRT being applied to that operation. Select this operation and click on

above.

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CONTROL KEY: You maintain the control key for operations in Customizing for Shop Floor Control. This is customizing operation. For SBT Scenario we are using 3 Control Keys viz. 1. PP01 - Routing/Ref. op. set - internal proc. 2. PP03 - Routing - in-house prod. auto. goods rct 3. PP07 - For Rework PP01 Is used for all Operations other than the Last Operation as it has a Auto GR Tick which will allow the components to be Goods received after the Final confirmation. PP03 Is used for the Last operation or where Goods Receipt is to take place. NOTE: Auto Goods Receipt can take place in 1 Operation only in the whole Routing sequence. PP07 This is specifically used for to be used in Rework Order operations. Manual GR is mandatory for Rework Orders.

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6.2 ADDING AN ALTERNATIVE ROUTING To add an alternative routing you have through TCode CA01 itself.

SAP ECC menu

Logistics → Production → Master Data → Routings → Standard Routings → Create

Transaction code

CA01

Here it would show that Sequence No. 1 with Group Counter 1 is the only one existing. Hence to create an Alternate Routing for the same FERT, i.e. if 1 Single Product is having more than 1 way of manufacturing the product. Click on NEW

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Here you can see the Counter as 2. Enter the Usage as 1 and Status 4 and click on Operations. Now you can enter the new sequence of operation that you want and give Enter.

Enter the Setup Time, Machine Time and Labour Time and SAVE.

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7. PRODUCTION ORDER CREATION – MANUAL – CO01 SAP ECC menu

Logistics → Production → Shop Floor Control → Order → Create → With Material

Transaction code

CO01

Enter the following: 1. Material Number:

XXXXXXXX

2. Production Plant:

1000

3. Order Type

ZS01

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Enter the following: 1. Quantity of Production 2. Basic Dates (As per the Scheduling Type)

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As we have an Alternative Routing for the FERT, you need to select the Icon Production Version in the top frame. It would then prompt you for the Routing which needs to be selected for the FERT as per the machine availability.

Select the required sequence and then you can continue as per the regular Production Order execution. PRE-REQUISITE FOR PRODUCTION VERSION: Production version needs to be maintained in Work Scheduling View or MRP4 View of the Material Master for the FERT’s who have more than 1 combination of BOM and/or Routings. Now, Click on the following: 1. Material Availability Check

It would show that the Material is available or not, if not it would mention that the material is shortage and material need to be made available at the required storage location.

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Click on the following: 1. Capacity Check

It would show whether the Capacity is Available or not.

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Click on the Calculator on the Top Frame, to calculate the costs. Thereafter the system should message as shown below.

Click on the Green Flag to RELEASE the Order.

System would show that the Order has been released. Now you can SAVE the production order and note the Production Order No.

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8. SHOP FLOOR PRINTING – PRODUCTION ORDER – CO04 SAP ECC menu

Logistics → Production → Shop Floor Control → Control → Print

Transaction code

CO04N

Enter the Production Order No. & Plant and give Execute.

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Select the Order description line and Press F8 (Execute).

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Select OWN SPOOL REQUESTS from the Pull Down Menu and select the latest Spool and select the printer to Print the Shop Floor Paper.

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The Production Order print can now be taken by the Production Supervisor and can move the same along with the Material being provided from IS01. Once the Production Order is printed the same cannot be printed as a New Print, it has to be printer as a RE-PRINT and the Heading would show DUPLICATE for the Shop Floor personnel’s to understand that it is a Duplicate Print of the prodcution Order.

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9. PRODUCTION ORDER CONFIRMATION – CO11n SAP ECC menu

Logistics → Production → Shop Floor Control → Confirmation → Enter → For Operation

Transaction code

CO11N

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As we would be Confirming the Order Operation Wise we can go for Time-Ticket Confirmation.

Enter the Order No. and the Operation which you want to confirm and Click on ACTUAL. DATA to get the Existing Data which has come along with the Production Order. Here you can now enter the ACTUAL Data which you have got through Production to be seen as the Variance during the Production Order reporting.

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Also select on Confirmation Type, for the Qty is to be processed and the reservations to be cleared, select Final Confirmation and Clear Open Reservations.

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Also you can click on Goods Movement

1

to enter the Actual material usage for

the Qty entered on the main confirmation screen.

Here you can see 2 Goods Movement i.e. Goods Issue and Goods Receipt to be happening in a Single Confirmation command. Thereafter click on SAVE. Check for any System Messages which appear in the Status Bar.

Now the material has been posted to QA for Quality Inspection. The same can be checked in the Stock Overview List of the FERT material.

Material qty. can be seen in Quality Inspection Stage.

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10. QUALITY INSPECTION – QA32 SAP ECC menu

Logistics → Quality Management → Quality Inspection → Worklist → Inspection → Change Data

Transaction code

QA32

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First check the Stock Overview MD04 for the FERT material.

You can check the QM Lot being created. The inspection of the components would be done in the QA Department and thereafter you can type in the TCode QA32 for viewing the Inspection Lot which has been created in the QA. In the Inspection Lot Enter Plant & Material who’s Inspection Lot is to be checked.

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Select the Inspection Lot which is to be confirmed after Inspection and click on Usage Decision Box at the top

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Select the Usage Code 04 GOODS RECEIPT FROM PRODUCTION  ACCEPT and Give ENTER and select on INSPECTION LOT STOCK

.

Here you can enter the Quantity which is OK, To Be Scrapped or to be moved to Block Storage. For E.g.: Total Qty.:

5 Nos.

Unrestricted Use:

3 Nos.

To Block Storage (Rework):

1 Nos.

To New Material (Scrap):

1 Nos.

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As the Scrap would be posted against a Pre-Defined Scrap material, say TEST-SCRAP, the Material has to be selected against “To New Material”.

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After the Usage Decision is Saved, selected Inspection Lot appears with a TICK mark on its left side and a Lot No. is created which can be seen at the System Status bar.

Click on REFRESH button to see the QM Lot being cleared (not appearing anymore in the list).

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You can also check the Stock Overview for this FERT component whose inspection has been done. The same can be done through Transaction Code MMBE.

Also you can see that the Qty has been reduced from Quality Inspection Stock and Qty. 3 nos. has been moved to Un-Restricted Use and 1 Nos. in Blocked Storage.

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11. PRODUCTION ORDER SETTLEMENT – KO88 SAP ECC menu

Logistics Production->Shop Floor Control->Period End Closing ->Settlement-> Individual Processing

Transaction code

KO88

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On the: Initial Screen, make the following entries: Field name

User action and values

Comment

Order

1000128

Example

Settlement period

10

Example

Fiscal year

2008

Example

Processing type

Automatic

Example

Deselect Test run & Select Check trans. Data. Click on Execute Button

Variance amount has been settled to the Price Difference account

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12. PRODUCTION ORDER TECO – (Technically Complete) – CO02 The production Order remains Open and Changeable until it is explicitly completed. In this context, distinction is made between logistical and the accounting based completion. TECO – After the completion of the production order the order is no longer logistically relevant; that is, it is marked as being no longer MRP relevant, and all the reservations for the components and capacity requirements that may still exist are deleted. The production order is assigned the status TCMP, which stands for Technically Completed (TECO). It is also now no longer possible to post any sots to the production order. Moreover, it is no longer possible to trigger any confirmation for the production order.

SAP ECC menu

Logistics → Production → Shop Floor Control → Order → Change

Transaction code

CO02

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After opening the order in Change Mode, from the pull down menu select, Functions->Restrict Processing -> Technically Complete. You can see now that the Order Status has now changed to TECO.

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13. CHECK PRODUCTION ORDER REPORTS SAP ECC menu

Information systems  General Report Selection  Production Planning Production Control

All the necessary reports for PRODUCTION PLANNING Module can be get from the above menu.

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13.1 PRODUCTION ORDER INFORMATION SYSTEM - COOIS The order information system is a tool for shop floor control and process industries with reporting functions for production orders, planned orders and process orders. Evaluations take place - as with the IOC logical database, via the original order tables.

SAP ECC menu

Information systems  General Report Selection  Production Planning Production Control  Order Information System

Transaction code

COOIS

On the Production Order Information System screen, make the necessary entries to run the report as desired.

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You can view all the orders in the system, including the orders with deletion flags or deletion indicators. Archived orders are not taken into account. The order information system has the following display options: 

In an individual object list, a list is generated for the selected object (for instance, order header, operation, and component). You can define the structure and appearance of the individual object list with a layout



On the object overview the individual orders are displayed with their subordinate objects in a hierarchical structure. With an overall profile, you can define which fields are displayed and which objects (order headers, items, sequences, and so on) are read or displayed. In addition, you can define which fields are displayed for the individual objects

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Reports regarding SCRAP / REJECTION can also be seen through this report where in you need to select CONFIRMATION as the header of the report.

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HEADER - ORDER WISE

HEADER - ITEMWISE

HEADER - DOCUMENTED GOODS MOVEMENT

HEADER - OPERATION WISE

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HEADER - COMPONENT WISE

HEADER - CONFIRMATION WISE

HEADER - AUTOMATIC GOODS MOVEMENT WISE

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13.2 CAPACITY PLANNING - STANDARD OVERVIEW – CM01 You can use capacity evaluations to analyze capacity loads in your company. You can adjust the analyses for each user according to the planning level, planning horizon and the area of responsibility. Available capacities and capacity requirements can be selected according to various criteria and cumulated using any period split you choose. You can use work center hierarchies to cumulate the available capacities of production work centers and their capacity requirements to superior planning work centers.

SAP ECC menu

Logistics  Production  Capacity Planning  Evaluation  Work Center View  Load

Transaction code

CM01

On the Capacity Planning: Selection screen, make the necessary entries to run the report as desired.

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In the capacity evaluation you can display the planned capacity requirements and the remaining capacity requirements

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13.3 CAPACITY PLANNING - CAPACITY EVALUATION – CM50 To Check all the Capacity Available for more than 1 Work Center.

SAP ECC menu

Logistics  Production  Shop Floor Control  Information System  Capacity Evaluation  Extended Evaluation Work Center View

Transaction code

CM50

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On the Capacity Evaluation : Selection screen, make the necessary entries to run the report as desired. Here you can get a complete capacity evaluation for more than 1 Work Center, i.e. a Range of Work Centers can be inputted here.

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Likewise, all the selected range of work centers can be seen here.

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13.4 ORDER PROGRESS REPORT – CO46 When you work with the order progress report, you can 

Choose the individual objects in the report in a flexible manner



Adapt the contents and the presentation of the report (for example, include hierarchy levels later)

 Execute functions (for example, convert planned orders) Go to object maintenance (for instance, Change production order)

SAP ECC menu

Logistics  Production  MRP  Evaluations  Order Progress

Transaction code

CO46

A progress report can be displayed for more than one sales order or a WBS element. The requirement elements and procurement elements are displayed. If you want to display all objects for a sales order, enter the sales order with item number. By entering a material or production order, you can further limit the number of objects displayed. If you want to display objects from the Project System, you have to choose a network or a material. The selected object (network or material) must be assigned to a WBS element. Depending on what you have entered, a structure is displayed, from which you can select a network or material.

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13.5 DISPLAYING PRODUCTION ORDER CONFIRMATION – CO14 You use this to display the confirmations of production orders.

SAP ECC menu

Logistics  Production  Shop Floor Control  Confirmation  Display

Transaction code

CO14

On the Display Production Order Confirmation: Initial screen, make the necessary entries to run the report as desired.

If several confirmations exist, the system branches to an operation overview containing the confirmations. Choose one or more confirmations. If you choose more than one confirmation then you can switch between confirmations in the detail display. You can print the operation overview and define a user-specific layout for it (column selection and sorting). If only one confirmation exists, the system branches directly to the detail screen for the confirmation.

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13.6 CHECK PRODUCTION ORDER DELIVERY – MB51 SAP ECC menu

Logistics → Material Management → Inventory Management → Environment → List Displays → Material Documents

Transaction code

MB51

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After selecting MB51 Enter filtering criteria’s such as Material, Plant, Movement Type, etc. Click on Execute.

st

2 highlighted in the Boxes displays the GR done 1 by Original Production Order and later through Rework Production Order.

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13.7 CHECK RAW MATERIAL ISSUE – MB51 SAP ECC menu


Transaction code

MB51

Enter and Input the Filtering criteria’s. Here we input 261 and 262 Goods Movement for Issuing of Raw material.

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13.8 CHECK RAW MATERIAL RECEIPT – MB51 SAP ECC menu


Transaction code

MB51

Enter and Input the Filtering criteria’s. Here we input 101 and 102 Goods Movement for Issuing of Raw material.

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This report would display the Total Receipt of Raw Material in the plant i.e. the Qty. which is being procurred externally. Note: Attached herewith is an Non-SBT example (as no live data is available at present in the System).

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13.9 MATERIAL USAGE ANALYSIS - MCRE SAP ECC menu

Information Systems → Logistics → Production → Material → Material Consumption

Transaction code

MCRE

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Enter the Plant and Production Order whose Material Consumption Analysis is to be done and click on Execute.

Click on Sujan Barre Thomas and click on Switch Drill Down and select the Level at which you want to analyze. Say you want to analyze at the Order Level, so select Order.

Here you can see the Total Requirement Qty (Planned Qty.) vs Withdrawal Qty. (Actual Consumption).

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13.10 ANALYZE PRODUCTION ORDER – KKBC_ORD Transaction code

KKBC_ORD

This will report based on Production as well as Accounting for a particular order. Enter the Order No. which is to be analyzed.

You can also select

Layouts to select which type of Report you would like to see for that particular

order.

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Say you select the first layout, Target/Actual – Comparison, now click on Execute. Select on

to select the required fields.

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13.11 CHECKING FAILED GOODS MOVEMENT - COGI SAP ECC menu

Logistics → Production-Process → Process Order → Environment → Material Movement→ Failed Goods Movement

Transaction code

COGI

You can check Errors in Goods Movement through COGI Transaction code.

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14. PRODUCTION ORDER – THROUGH DEMAND MANAGEMENT 14.1 CREATE PLANNED INDEPENDENT REQUIREMENT – MD61 As part of material requirements planning using the net change method, the planned independent requirements are exploded across the entire BOM structure. As a result, the system also determines dependent requirements for purchased parts and raw materials.

SAP ECC menu

Logistics → Production → Production Planning → Demand Management → Planned Independent Requirement → Create

Transaction code

MD61

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On the Create Planned Independent Requirement: Initial Screen, enter the following data: Field name

Description

Comment

Planned Independent Requirements for Material

Enter Material Code.

Finished Good MTS (You have to select the radio button)

Plant

Enter Plant Code.

Always Enter Production Plant.

Select Verson Number.

Always select Active Version

From

From Date

To

To Date

Change system default if necessary.

Selection parameters Version Planning horizon

Planning period

Select the appropriate Planning Period

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Check the Stock Requirement List for the same through MD04.

The Independent Requirement which is generated can be seen here in the RED box being highlighted.

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14.2 MRP – AT PLANT LEVEL – MD01 MD01 is used for running the MRP for specific plant or number of plants to maintain the scope of planning. In the scope of planning you can maintain number of plants and can use the scope to run MRP for maintained plants. Usually this is followed when the First MRP is run at the time of first Run in Production Environment. Thereafter MRP is run at Material Level i.e. MD02. So if you want to run MRP for all plant and material in that case we use MD01

SAP ECC menu

Logistics → Production → MRP → Planning → Total Planning→ Online

Transaction code

MD01

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14.3 MRP – AT MATERIAL LEVEL – MD02 MD02 is used to run MRP for a particular Material. This run would be for just one material , single item , multi level ( will explode whole BOM for particular material )

SAP ECC menu

Logistics → Production → MRP → Planning → Total Planning→ Single Item, Multi Level

Transaction code

MD02

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Enter the following details: 1. Enter Material Name 2. Enter Plant 3. Select Processing Key Specifies the type of MRP run. The following types are possible: 

net change planning: NETCH



net change planning in the planning horizon : NETPL



online regenerative planning : NEUPL

4. Create Planned Order / Purchase Requisitions (In case of BOP) 5. Delivery Schedules: Whether To Create or No 6. Create MRP List 7. Planning Mode & Scheduling Above details are shown in the image above. ENTER to run the MRP. An MRP List will be generated.

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Now the Planned Orders will be generated for this PIR. Through MD04 you can select this Planned Order. Shown below.

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Select the Row of Planned Order, and Click on CONVERT TO PRODUCTION ORDER through this Icon

.

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Clicking on this, will take you to the Production Order Screen. Enter the following: 3. Quantity of Production 4. Basic Dates (As per the Scheduling Type)

Click on the following: 1. Material Availability Check

It would show that the Material is available or not, if not it would mention that the material is shortage and material need to be made available at the required storage location.

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Click on the following: 2. Capacity Check

It would show whether the Capacity is Available or not. Click on the Calculator on the Top Frame, to calculate the costs. Thereafter the system should message as shown below.

Click on the Green Flag to RELEASE the Order.

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System would show that the Order has been released. Now you can SAVE the production order and note the Production Order No.

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Refresh the Stock Requirement List (MD04) to see the Planned Order being now converted to status Production Order (Shown in red box below).

Shop Floor Printing can be performed thereafter through Transaction Code: CO04N.

SAP ECC menu

Logistics → Production → Shop Floor Control → Control → Print

Transaction code

CO04N

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14.4 PRODUCTION ORDER CONFN. WITH REWORK – CO11n SAP ECC menu


Transaction code

CO11N

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Enter the Order No. and the Operation which you want to confirm and Click on ACTUAL. DATA to get the Existing Data which has come along with the Production Order. Here you can now enter the ACTUAL Data which you have got through Production to be seen as the Variance during the Production Order reporting. As we would be doing REWORK activity in this Production Order, we can first check the Stock for the part across the plant through T Code MMBE.

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On confirmation screen let us consider 200 as Yield Qty. and 100 as Qty. which is to be REWORKED.

Save the Confirmation Check for any System Messages which appear in the Status Bar.

Now the material Qty. 200 has been posted to QA for Quality Inspection. The same can be checked in the Stock Overview List of the FERT material.

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You can go back to CO02 for Production Order No. 100123 to see the status of the Qty.

Here you can see that out of the Total Qty. Delvrd is 200 and 100 is reworked which can be seen through Operation Overview at the extreme Right End.

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14.5 PRODUCTION ORDER CREATION – REWORK – CO07 SAP ECC menu

Logistics → Production → Shop Floor Control → Order → Create → Without Material

Transaction code

CO07

PRE-REQUISITIES: For Rework Order Following Pre-Requisites have to be followed. 1. A separate Rework Order has to be Created without Reference to any Material. 2. Goods Receipt for a Rework Order has to be done manually.

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Production Order Initial Screen will appear. Here enter Production Plant & Order Type for that Rework Order.

GENERAL TAB Thereafter on the Header Screen, Enter the following: 1. Material Description 2. Total Qty. to be reworked and Its Unit of Measurement 3. Basic Dates

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After giving ENTER it would give a Dialogue Box.

Here select on GENERATE OPERATION. On the next Screen, i.e. Main Settlement Rule: Overview enter the following: 1. Category: ORD (i.e. to be settled against a Production Order) 2. Settlement Receiver: Production Order No. (In this case it is 1000123) & give ENTER. Here it will now show the relevant details.

Go Back now.

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ASSIGNMENT TAB 

Enter MRP Controller



Enter Profit Center

GOODS RECEIPT 

Control Data: Stock Type ; X – Quality Inspection

Thereafter Click on Operation Overview Icon Select the following: 

Work Center on which the rework is taking place



Control Key: PP07 (For Rework Production)



Can also enter the Operation Description and give ENTER.

Thereafter Click on Component Overview

to enter the components to be processed.



Enter the Component to be reworked.



Enter the Quantity (can be calculated through CS11 for total requirement as per the rework quantity).



After entering the details and giving ENTER it would ask for the Operation Assignment, i.e. the component is to be assigned to which Operation. Select the operation and give Enter. Also check for the Storage Location i.e. from where the Material will be issued, which should be IS01 in our case.

Go back now.

Like a Normal Production, Check for Material Availability, Capacity Availability, Pre-Cost it and then Release the Rework (Production) Order and Save it and note the Rework Production Order No.

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14.6 REWORK PRODUCTION ORDER CONFIRMATION – CO11n SAP ECC menu


Transaction code

CO11N

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Enter the Order No. and the Operation which you want to confirm and Click on ACTUAL. DATA to get the Existing Data which has come along with the Production Order. Here you need to enter the ACTUAL Data which you have got through Production as the same will not be copied.

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Check for any System Messages which appear in the Status Bar.

Now the material has been posted to QA for Quality Inspection. GR for the order needs to be done manually.

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14.7 GOODS RECEIPT OF REWORK ORDER – MB31 SAP ECC menu

Logistics → Production → Shop Floor Control → Goods Movement → Goods Receipt

Transaction code

MB31

NOTE: Goods Receipt for a REWORK Order has to be done manually. Auto GR is not possible. Now, here enter the following: 

Movement Type: 101



Order No. would be the parent Production Order, 1000123



Plant : 100



Storage Location : FG01

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After entering select the item No.1

Click on

And SAVE. You can see the Document No.

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You can go back to the Order 1000123 and see that all the 300 Nos. have been delivered.

Components are now posted to QA, which can be checked through MMBE

Hereafter the QA Cycle can be followed Index Point No. 11 to clear the Production Order.

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15. MRP – FOR PLANNED ORDER + PURCHASE REQUISITION So far we have seen MRP being run to generate PLANNED ORDER further to generate Production Order to be run in Production environment. Now here we would see the MRP to be run to generate Planned order as well as Purchase Requisition by a Single MRP Run through MD02. MD02 is used to run MRP for a particular Material. This run would be for just one material , single item , multi level ( will explode whole BOM for particular material ).

SAP ECC menu

Logistics → Production → MRP → Planning → Total Planning→ Single Item, Multi Level

Transaction code

MD02

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Here we take another Material as an Example. FERT Material: TEST-FG12 Requirement in MD61 : 35 Qty.

First we check the existing Stock for TEST-FG12 through MD04.

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Enter the following details: 1. Enter Material Name 2. Enter Plant 3. Select Processing Key Specifies the type of MRP run. The following types are possible: 

net change planning: NETCH



net change planning in the planning horizon : NETPL



online regenerative planning : NEUPL

4. Create Planned Order / Purchase Requisitions (In case of BOP) 5. Delivery Schedules: Whether To Create or No 6. Create MRP List 7. Planning Mode & Scheduling Above details are shown in the image above. ENTER to run the MRP. An MRP List will be now generated.

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Now we go back to MD04 to check the Stock.

We can see that NO STOCK is available to Manufacture the FERT, shown as “0” in Available Qty. in BLUE colour. Click on the Eye Glass to get the new Dialogue Box.

Now click on

to see the Order Report.

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Here you can see the Components which are contained in that FERT. And can Browse through, by Double Clicking on the components to check the availability and the List below will show the latest Stock position for that particular component. Say we Click on IT-ROH03 (ROH material, whose Purchase Requisition is to be created).

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Here the one shown in RED Box, is the Planned Order which can be converted to Purchase Requisition. Click on Eye Glass.

Click on PUR. REQ. in the new dialogue Box. It will take you to Convert Planned order to Purchase Requisition : Details Screen. Here you can related information details such as, Storage Location (say ST01) and SAVE it. You will get a Confirmation Message.

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REFRESH the list. Now you can see the List has been updated as shown in the RED BOXES below.

Further more, a PURCHASE ORDER can be created through PURCHASE REQUISITION. If release Strategy has been set for Purchase Requisitions, the PR needs to be released before it is converted to Purchase Order. This activity would be done by Purchase Dept. personnel.

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16. CO-PRODUCT SCENARIO Products that are usually manufactured together can be produced using one production order. The main product is the primary reason for the production process. It is displayed in the production order header. The system also creates a separate order item for the main product. A co-product is a product that is produced in conjunction with other products. The system creates a separate order item in the production order for each co-product. As a result, it is possible to display actual costs at co-product level. Creating a production order to manufacture co-products has the following advantages: 

Main product and co-product(s) are settled to different receivers



Goods movements can be posted simultaneously for all products manufactured in the order.

Pre-Requisities The following prerequisites must be fulfilled if you want to create a production order with co-products or by-products. Prerequisite for the main product: The indicator Co-product must be activated in the material master of the main product (MRP area) Prerequisites for a co-product: 

The indicator Co-product must be activated in the material master of the co-product (MRP area)



The co-product must be listed as an item in the bill of material of the main product with a negative value.



On the Basic data tab page of the BOM item, the indicator Co-product must be activated in the field group General data.

Example: Say we have a Family Mould with 2 Family Components viz 1. TEST-COP01 2. TEST-COP02 Now say we want to take the Production of these 2 Family FERT’s.

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Say we consider the Header / Main Product is TEST-COP01 we create a Production Order for this Header Material. BOM For TEST-COP01 would be as seen below.

Highlighted in Red is the Famiyl Component with –ve (negative) Quantity. When we check the Production Order it would show it as follows.

NOTE: GR for such an Order for a Co-Product scenario has to be done MANUALLY by MB31. Also, whatever the Rejection / Scrap which is going to get posted will be of the Main Product whose Production Order is being made.

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To Summarize: 1. A co-product is a product that is produced in conjunction with other products. The system creates a separate order item in the production order for each co-product. As a result, it is possible to display actual costs at co-product level. 2. The main product is the primary reason for the production process. It is displayed in the production order header. The system also creates a separate order item for the main product. 3. The indicator Co-product must be activated in the material master of the main product (MRP 2) as well as the Co-Product. 4. The co-product must be listed as an item in the bill of material of the main product with negative Qty. 5. On the Basic data tab page of the BOM item, the indicator Co-product must be activated in the field group General data.

6. Production Order would be of the Main Product, hence also the Confirmation and scrapping would be of the Main Product Only. 7. Production Qty mentioned in the Production Order, say Qty. 10 means 10 Qty. of Co-Product 1, and 10 Qty. of Co-Product 2. 8. Raw Material qty. to be issued would be the qty. required to product both the co-products. 9. In Production Order you need to maintain the settlement Rule in pull down menu i.e. Header -> Settlement Rule 10. You cannot post Auto-GR for Co-Products. You have to follow Manual GR by MB31 101 Movt. 11. If you want to scrap co-product do the following steps. 

Confirm all the qty as yield qty in . ( ok + scrap)



Do goods receipt for main product & co-product (total qty).



Physically you know the how much rejected qty. Move that qty from accepted str location to rejection str location by using MB1B 311 mvt.



Now yield qty will reduce.



Check in MB51 with mvt type 311 with corresponding period, you came to know how much quantities are rejected.



By 551 mvt materials scrap that rejected qty.

12. But if you want the Sell the scrap, then follow the following steps: a. Confirm all the qty as yield qty ( ok + scrap) b. Do goods receipt for main product & co-product (total qty). c.

Scrap the Material to a Scrap material, say SCRAP-MATERIAL through QA32 (QM).

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Suppose you have a Co-Product scenario for LH & RH of a particular FERT. In this case you want to run only a few nos. of Cavity of RH keeping the nos. of cavities of LH running as it is. In that case follow the below mentioned procedure. Most important of all you need to maintain the Base Qty. relation of the 2 co-products. Say for 4 Components of LH you want only 2 Components of RH. Here you need to maintain in BOM of LH the following: 

Select the Co-product with negative value (i.e. RH) and double click on Item No. to enter detail information



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

After entering, on the Basic Data Screen, maintain the negative Qty. as 0.50 –



Now you can go ahead and create the production order.



Now you will get only 2 Components of RH for 4 components of LH. Shown is the Production Order.

One important thing to remember here is that the Cost apportionment is to be maintained accordingly in Settlement rule.

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