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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
ConfigurationDocument
PRODUCTION PLANNING
Version Date Title /Module Prepared /Changed
01 01.03.2008
Configuration Document
PRODUCTION
PLANNING
PP Consultant
K.Sudhir Goud
SAP R/3 version : mySAP ERP ECC 6.0
Project Manager(Bigtec Pvt Ltd): Mr. Chinmoy K Patnaik
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
BASIC DATA BILL OF MATERIALS SPRO :
PATH> Production ~ Basic Data ~ Bill of Material ~ General Data ~ BOM Usage ~
Define BOM Usages.
In Bill of materials side of production the details of the Items and the header in the
transaction CS01, CS02, CS03 were the SAP Easy Access screen involved to be changed
if we are doing the changes in the below screens.
PATH> Production ~ Basic Data ~ Bill of Material ~ General Data ~ BOM Usage ~
Define Default Values for the Item Status
Here in this screen the production relevancy in the BOM and the Costing Relevancy will be
carried and default settings will be there automatically triggered or flagged / marked as X
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Bill of Material ~ General Data ~ BOM Usage ~ Define
Material types allowed for BOM Header
In these criteria the BOM Usage 1 will be used for the production and applicable to all the
material types ROH, FERT, HALB, ESRA, VERP etc. Material Type header the allowanced is
positive and it is known for all the material types and it is masked as *
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Bill of Material ~ General Data ~ BOM Usage ~ Define
BOM Status
The BOM Status will be Active for our purpose since it will be involved all the production
relevant activities. It will be evolved during the MRP Explosion, Planned order, Relevant to
costing, Relevant to Work Scheduling, Sales etc.
PATH> Production ~ Basic Data ~ Bill of Material ~ Item Data ~ Define Item Categories
The Item Categories for the production relevant activities and the goods movements will be
applicable to the Stock Items represented by L. It will be used in the inventory management
with item control 0001 and the material input will be for all hence it is represented as +
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Bill of Material ~ Item Data ~ Define Allowed
material types for BOM Items
Material type header and the Material type BOM Items will be allowable for the usage
production
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Bill of Material ~ Item Data ~ Item data from
Related Application Areas ~ Define Relevancy to Costing
Applicable for 100% relevancy to costing indicated as X for all the BOM items to be done for
full costing of all the items. The costing relevancy can be also changed if needed to less cost
evaluations
PATH> Production ~ Basic Data ~ Bill of Material ~ Item Data ~ Alternative
Determination ~ Define Applications
In this Specific Criteria for Alternative Determination in Application areas of production the
PP01 with selection ID 01 wit alternative selection ID, production version, MRP Explosions,
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
Work scheduling, planned orders and the relevancy to costing are flagged to link the
application
PATH> Production ~ Basic Data ~ Bill of Material ~ Item Data ~ Alternative
Determination ~ Alternative Determination in Related Application Areas ~ Define
Alternative determination for production
For our production plants 1100,1200 & 3200 we had defined the Application PP01 and
linked the same to the Order types in production for BOM explosion during the
production order / Planned order creations
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PRODUCTION BASIC DATA WORKCENTRE:
PATH> Production ~ Basic Data ~ Work Centre ~ General Data ~ Define Work Centre
category
In the work centre Assembly sections where we can define the categories for Machine and the
Labor. the work centers.
Field selection and the screen sequence is a standard one in the SAP
The applications for our category of the work centers are the areas like
P Routings for production (applicable to production)
Q - Inspection plans
I Maintenance task lists
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Work Centre ~ General Data ~ Define task list Usage
The task list usage is used to identify the production usage evaluation and it is defined as
0001 Only routings and then 009 - for all task list types and is applicable to all the task lists
in inspection plans, in networks, in maintenance task lists , production rate planning, in rate
routings and in master recipe + process order
Usage 009 is applicable to us and it is generated in the production.
The task list type is one of the important one used to fix the evaluations and the applicability
to which kind of lists used.
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
It is mentioned for Master recipe, Rough Planning profile, general maintenance task list,
Equipment task list, Reference rate routing, Inspection plan and Routing (N). This type N isused for our production
PATH> Production ~ Basic Data ~ Work Centre ~ General Data ~ Standard Value ~
Define Parameters
The Parameters are the useful one for the Standard Value Key and the base unit with
dimensions and the origin which takes place in the operations were displayed.
SAP_01 for Setup Time, SAP_02 for Machine
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
SAP_03 for Labor were involved
The parameters and their details are below
Standard Value unit can be Minutes, seconds and hours for operations in SETUP, CYCLE
TIME Labor and Machine
PARAMETERS SETUP TIME :
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PARAMETERS MACHINE :
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Work Centre ~ General Data ~ Standard Value ~
Define Standard value key
In our case 2 standard value keys are defined one Normal Production
PATH> Production ~ Basic Data ~ Work Centre ~ General Data ~ Standard Value ~Define Person responsible
Specific persons involved in the work centre as planner for different plants 1100,1200 &3200
were defined and it can be called in the work centre.
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Work Centre ~ Routing Data ~ Define Control key
Control key plays a role in the work centre as a default value if the flag (Reference indicator)
is done in the same which reflects in routing.
PP01 control key plays scheduling, capacity requirements, Print time tickets, Print
confirmation, print and the cost with milestone confirmation
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Work Centre ~ Capacity planning ~ Define capacity
categories
The Capacity categories were applicable for Machine and person as per the area of work and
the Assembly areas. Machine 0001 is used and Person 0002 is used in the Assembly
PATH> Production ~ Basic Data ~ Work Centre ~ Capacity planning ~ Define capacity
Planner
capacity planner group 1 as who is planning for the machine or area. It can be a group or
person
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Work Centre ~ Capacity planning ~ Work centre
Formulas ~ Define formula for work centers
This formula is used for scheduling for machine hours in work centers
For set up time the following formulas are used
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
In 1100, 1200&3200 for machine hours the following formula is used
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
Scheduling formula
Costing and capacity requirements formula
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PRODUCTION BASIC DATA ROUTING SPRO:
PATH> Production ~ Basic Data ~ Routing ~ General Data ~ Define Material type
Assignments
Here the assignment to different Material Types with task list type N for FERT, HALB and
ROH is linked
PATH> Production ~ Basic Data ~ Routing ~ General Data ~ Define Routing Statuses
Task List statuses were of 4 types and it is collectively described. It is for the created stage,
released for the order, released for the costing and the Released (general) which is done for
our scenario
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Routing ~ General Data ~ Define Task List Usage
For the Usage 1 Production is done for the material
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Basic Data ~ Routing ~ Routing Selection ~ Select Automatically
This Automatic selection in the routings with Task List N Production with released general
and the plan .
PRODUCTION PRODUCTION PLANNING DEMAND MANAGEMENT (PIR) :
PATH> Production ~ Production Planning ~ Demand Management ~ Planned
Independent Requirements ~ Requirements Types / Requirements Classes ~ Define
requirements types and allocate requirements class
The Requirements Types gives the scenario whether it is a Make to Stock or Make to Order
with a type LSF which is linked to the Requirement class of 100 and mapped to the strategy group which is the effect which takes places in the material master MRP3. This group is
linked to the Independent requirement of the planning.
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Production Planning ~ Demand Management ~ Planned
Independent Requirements ~ Planning Strategy ~ Define Strategy Group
The planning strategy used for our scenario is the Gross requirement Planning group 11
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PRODUCTION MRP:
PATH> Production ~ Material Requirements planning ~ Plant Parameters ~ Carry out
Overall Maintenance of Plant Parameters
When we maintain the plant parameters for manufacturing plant, the number ranges for the
planned orders, production orders, purchase requisitions, MRP lists must be maintained.
Backorder check rule 02 must be maintained. MRP controllers for the and the Assembly
divisions, Floats (i.e.) the Schedule margin key like opening period, before production, after
production and release period to be maintained. BOM and routing selection control to be
maintained. Rescheduling concepts and planning horizon for the period to be maintained.
Availability stock concepts to be done
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Configuration DocumentPRODUCTION PLANNING
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PATH> Production ~ Material Requirements planning ~ Master Data ~ Define MRPControllers
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Material Requirements planning ~ Master Data ~ Check MRP
Types
The Normal MRP maintained is PD and it is the one which is in the MRP fields in the
Material masters which takes place in the planning and it links to the strategy
MRP Type and the MRP Procedure with all the parameters are maintained in the screen
sequence.
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Material Requirements planning ~ Planning ~ Scheduling and
Capacity parameters ~ Define Floats (Scheduling Margin Key)
For the plant 1100,1200&3200 the scheduling margin key is 000 which is been highlighted
with no values in the opening period, float before production, float after production and the
release period.
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Material Requirements planning ~ Planning ~ Scheduling and
Capacity parameters ~ Define Scheduling parameters for planned orders
In these scheduling planned orders the masked order type is applicable to all the orders with
production scheduler. If clicking the overview of the highlighted one we can see the details
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
The details of the above is explained with Selection ID as 01 for the detailed scheduling and
the scheduling and the generate capacity requirements were flagged. Other rate-based andRough-cut scheduling plays no role.
Also the scheduling level wise detailed scheduling with adjusting the basic dates, adjusting
dependent requirements to operation dates / capacity scheduling for the basic dates and thedependent requirements to the operation dates were done
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Material Requirements planning ~ Planning ~ Scheduling and
capacity Parameters ~ BOM Explosion ~ Define BOM Selection
Here the BOM selection ID is maintained as 01 with released general 04 which is highlighted
PATH> Production ~ Material Requirements planning ~ Procurement Proposals ~
Planned Orders ~ Define Availability check for Components
This availability check plays in the production with checking rule and the MRP maintained in
the material masters for the plant. It can be maintained for the Group also
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
The checking rule 02 is made in the material masters and it must be linked in the availability
check also
The individual requirements and the checking rule 02 which checks the availability of
components in the production order creation stage / release stage
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Material Requirements planning ~ Planned file Entries ~ ActivateMRP and set up Planning File
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
This Activation of the Material requirements planning and consistency check in the planning
file entry
For the plant 1100, 1200 &3200 which are manufacturing plants must have the flagging in
the Activate requirements planning
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PRODUCTION SHOP FLOOR CONTROL:
PATH> Production ~ Shop floor Control ~ Master Data ~ Order ~ Define Order Types
These Production Order Types with Order category 10 and the Order type JP01,BP01,SP01with control indicator Partner Update with Semi active and links with the Settlement profile
which is mentioned below for better Cost controlling in the functional area production .This
links with the controlling part
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Configuration DocumentPRODUCTION PLANNING
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PPMMPPLL
PATH> Production ~ Shop floor Control ~ Master Data ~ Order ~ Define Order Type
Dependent parameters
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
The details of the above Order types dependent parameters are described below.
In the Planning, it links to the Production version, Routing and task list, Operations with
increment 10 and the Bill of materials application PP01
In the Controlling screen of the continuation the Controlling plays a role with the order type
by defining the same for Planned and Actual costing variant PPP1 / PPP2, Result analysis
key for the Work in Progress calculations and the planned costs when saving the order.
We have to maintain the default rule PP1 for the material full settlement.
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Shop floor Control ~ Master Data ~ Order ~ Define Number
Ranges for orders
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
These maintained above are the internal and the external number ranges of the Order.
Flagged one is the external number range and the highlighted one is the internal number
ranges with current number displayed
PATH> Production ~ Shop floor Control ~ Master Data ~ Order ~ Define Number
ranges for confirmations
Here the number range interval is only for the internal numbers and the current number of
the same is also displayed
PATH> Production ~ Shop floor Control ~ Operations ~ Bill of Material Selection ~
Define Priorities for BOM Usages
The order priority of the BOM usage is used for the selection ID and the selection profile with
the production
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Shop floor Control ~ Operations ~ Bill of Material Selection ~
Define Applications
Production general for the application PP01 with selection ID 01 with alternative selection
and the production versions are linked in this application specific criteria for alternative
determinations.
It gives the explosion of the MRP / Planned order / Relevancy to costing / Relevant work
scheduling and the release of the order
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Shop floor Control ~ Operations ~ Availability Check ~ Define
Checking Group
The availability check in the material masters MRP 2 view and the individual requirements
with total sales and total delivery requirements
PATH> Production ~ Shop floor Control ~ Operations ~ Availability Check ~ Define
Checking Rule
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Shop floor Control ~ Operations ~ Availability Check ~ Define
Checking Control
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
In the standard one of the production order the availability check for the business function 1
order creation time availability check will be carried out
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
Here we mentioned for the order creation no check of material, PRT and the capacity.
In the business function 2 (i.e.) the availability check during the order release the material
availability is checked for the order in the released stage.
PATH> Production ~ Shop floor Control ~ Operations ~ Scheduling ~ Define
Scheduling Parameters for Production Orders
These scheduling parameters for the order type PP01 for the masked production scheduler is
displayed.
The detailed view of the scheduling parameters been displayed.
The scheduling dates are adjusted as per the basic dates and adjust dependent requirements
to operation dates with scheduling type backward
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
PATH> Production ~ Shop floor Control ~ Operations ~ Confirmation ~ Define
confirmation parameters
For the plants the confirmation parameters is liked to the order types
In this control the general valid settings with operation sequence checking, under delivery and over delivery tolerance checking and the message of the quality inspection results also
exists.
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
In the second areas of the general individual entry the partial confirmation is allowed for the
confirmation type.
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
In the second areas of the general individual entry the partial confirmation is allowed for the
confirmation type
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
In the 3rd view the operation individual entry usage for the quantities, dates, screen control
for the time ticket and the services with HR up dating exists
PATH> Production ~ Shop floor Control ~ Integration ~ Order Costing ~ DefineSettlement
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
The profile for the settlement is defined and the details are as follows.
Allocation structure and the source structure also been defined for the impact in the costing
and controlling
The settlement is full settlement to the material order items with 100% by flagging the
equivalence numbers and the variances to costing based profitability analysis and making the
Order item as settlement optional
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Configuration DocumentPRODUCTION PLANNING
Project:e-Jagruti
PPMMPPLL
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