PP Master Data Configuration

SAP PP/QM Configuratio
n

INDEX

1. OVER VIEW:- 4

2. GETTING INTO THE CONFIGURATION AREA OF SAP 8

3. MASTER DATA CONFIGURATION - BOM 12

3.1 Define BOM Usage 12

3.2 Define Default Values for item status 16

3.3 Define Allowed Material type for BOM Header 20

3.4 Define BOM Status 23

3.5 Define Item Category 26

3.6 Define Allowed item type for BOM Item 30

3.7 Define Explosion types 33

3.8 Define Order of Priority 36

3.9 Define Application 40

3.10 Define Alternative Determination for Multiple BOM 44

3.11 Alternative determination in related application Area 46

3.12 Define User-specific setting 47

4. WORK CENTER 50

4.1 Define Work center Category 51

4.2 Define Field Selection 54

4.3 Define Task List usage 58

4.4 Define Parameters 61

4.5 Define Standard Value 65

4.6 Determine Person Responsible 69

4.7 Define Control Key 71

5. CAPACITY PLANNING 76

5.1 Define Capacity Category 76

5.2 Determine Capacity Planner 78

5.3 Define Shift Sequence 81

5.4 Define Formula Parameters for Work centers 88

5.5 Define Formula for Work centers 91

5.6 Define Factory calendar 95

5.7 Define Default Capacity 106

5.8 Define Work center screen sequence 109

6. ROUTING 112

6.1 Define Standard value description in operation over view 113

6.2 Define Routing Status 115

6.3 Define Task List usage 117

6.4 Define Reduction Strategy 119

6.5 Define User Fields 123

6.6 Define Routing Selection Automatic 127

7. SUMMARY:- 130

1. Over view:-

Production Planning module configuration and relevantreports are demonstrated in this book.

PP module contains three types of manufacturing methods.

o Discrete

o Repetitive

o Process Industries.

Discrete: -

Discrete production method is applicable to the manufacturingsetup where small lots are manufactured with frequentchanges in the settings.

Manufacturing is accounted through Production orders.

Repetitive: -

This method is applicable, where products are manufacturedwith least change or no change in the manufacturing processover a long period of time.

Manufacturing is accounted through backflush.

Process Industries: -

It is similar to the Discrete but instead of routing, It usesmaster recipe where in Process messages are maintained.

It is more appropriate to the food industries and processingunits where instructions are used during the process.

Manufacturing is accounted through process orders.

Configuration setting in PP module can be classified as below.

• Master Data related settings

• Planning Related Settings

• Production Execution related settings

We will discuss about the Master data related configurationsetting in detail.

Important Master data in PP module are

• Bill Of Material

• Work center

• Routing

Bill Of Material (BOM):-

BOM can be defined as “a list of required components alongwith the required quantity essential to make any product”.

Important Technical details related to BOM are

Application of BOM

Usage of BOM

Status of BOM

Selection of BOM

Configuration setting related to BOM will enable to align theBOM master data in line with the business requirement blueprint document.

Work Center:-

Machines, group of labour, processing unit are defined aswork center in SAP.

Work center contains the

Capacity Requirements

Scheduling details

Costing details

Configuration setting related to work center will enable todefine the SAP system according to the business requirementblue print document.

Routing:-

Sequence of operation, work centers to be used and theduration required for each operation to manufacture theproduct is defined in routing.

Important Technical details related to Routing are

Usage of Routing

Status of Routing

Selection of Routing

Configuration settings related to Routing will enable to alignthe Routing master data in line with the business requirementblue print document.

Friends, the configuration settings related to each master dataare explained in detail.

Example:-

BOM

Item category configurationAutomatic alternate selection of BOMConfiguration of BOM usageConfiguration of allowed item type for BOM

Work Center

Configuration of field selection in work centerConfiguration of formula to schedule and calculate costConfiguration of standard value keyConfiguration of shift sequence

Routing

Configuration of Automatic Routing selectionConfiguration of Routing usageConfiguration of reduction strategyConfiguration of user defined fields in Routing

2. Getting into the Configuration area of SAP

BACKGROUND

To make the configuration in SAP, one has to haveauthorization to perform transaction in configuration mode.

It is the place where every details are maintained to make thetransaction happen as per the business mapping.

SCENARIOIt is required to configure various settings in SAP.

INSTRUCTIONSTo do configuration, first one has to logon to the system, andgo to the IMG mode. How to logon to IMG mode is explainedbelow. From next document onwards, it is mentioned as IMG.

How to get in to the SAP IMG mode?

1. Type spro in the SAP main screen dialog box,

2. Click

3. Click on

Note:- Production related configurations are available under Node.

4. Click

5. You are inside the IMG for Production Planning Module.

If the menu path is mentioned as “IMG” in the furthertopics, you have to follow the above step to reach this place.

3. Master Data Configuration - BOM

3.1 Define BOM Usage

BACKGROUND

This configuration setting enables to define Bill Of Material(BOM) usage.

BOM usage defines the usage of BOM in specific applicationarea in the SAP.

Example, there can be a separate BOMs for

Ø Design,

Ø Production

Ø Costing.

In this way, each area is dealing only with the specific data itrequires.

Example:

Ø The design BOM includes all the components of theproduct and their technical data from the design point ofview. This BOM is generally not linked to any order.

Ø The production BOM contains all the items required fromthe production and assembly point of view. Only itemsrelevant to production, for which production data (suchas the issue storage location) can be entered, arerequired. A production BOM does not contain anypackaging materials required in the shipping department.

SCENARIO

Create new BOM usage.

Note:-

Standard BOM usage available with SAP is sufficient. Howeverany new BOM usage can be created.

INSTRUCTIONSFollow the Menu Path: IMG → Production → Basic data → Billof materials → General data à BOM Usage à Define BOMUsage

1. Click

2. Click

3. Enter usage value; it can be either numeric or alphabet.It is suggested to be numeric.

4. Select +,- or . to indicate to which area this BOM ismeant for like Production, Engineering, Spare, PlantMaintenance, Sales or for costing relevancy.

Note:-Based on this, during BOM explosion, entiredependent requirements are also planned,

5. Enter Usage text

6. Click Save

Impact of this configuration in Master Data /Transaction

When creating the BOM, key defined here will appear in theBOM Usage field.

According to the requirement, BOM usage key has to beselected during BOM Creation.

Click Match code or F4 in BOM usage field, to select thedesired BOM usage.

Transaction code to create BOM is CS01

3.2 Define Default Values for item status

BACKGROUND

This configuration setting enables to define default values foritem status.

Every item in the BOM can be defined whether it is subjectedto Costing

Sales

Production

Spare part

This configuration setting is used to indicate whether the BOMcomponent along with the BOM usage.

Ø is to be considered for costing in this BOM or not,

Ø is relevant to sales (normally used in Variantconfiguration),

Ø is a spare part

Ø is related to Production

SCENARIO

Set the default value for items in BOM.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsàGeneral dataàBOM usageàDefine default valuesfor the item status

1. Click

2. Click

3. Enter Usage value

4. Update the following fieldsField Name Description ValueBOM usage Field defining the

BOM usageEnter value e.g. 1

Prod Indicating that theBOM item is relatedto Production

Make tick in thecheck box

Eng/des Indicating that theBOM item is relatedto Engineering andDesign

Leave blank.

PM Indicating that theBOM item is relatedto Plant

Leave blank

MaintenanceSales Indicating the item

is related to Salesand it will appearin the sales order.

Leave blank.Normally used invariantconfiguration.

Relevan Relevant to costing Select X , indicatingrelevant to costing.

5. Click Save .


Example:-

BOM usage defined 1 indicating relevant to production. Theitem status as configured such that all items

Ø are relevant to production

Ø can be relevant to costing

In this example, the indicators are checked as follows:

Ø The Indicator: item relevant to production cannot bedeselected (required entry). In the BOM maintenancefunctions, this indicator is set automatically for all itemsand cannot be cancelled.

Since the item can be relevant to costing, the default valueX (fully relevant to costing) can be set for the Indicator forrelevance to costing. This value can be overwritten in theBOM maintenance functions.

BOM item level default setting will appear as per the settingdone here.

3.3 Define Allowed Material type for BOM Header

BACKGROUND

This configuration setting enables to control the creation ofBOM to the specific material types.

This configuration is done to the combination of BOM usageand Material type.

When a new bill of material is created, the system checks thematerial type as follows:

§ The fully qualified (non-generic) entries are checked first.The generic entries are checked afterwards.

§ You can define that the use of the material type incombination with Creation of BOM with respect to materialtype can be controlled.

Example, it may not be allowed to create BOM for Rawmaterial. (Material type ROH).

Creation of BOM to material type ROH can be restricted in thesystem.

SCENARIO

Creation of BOM for Material type ROH should not be allowed.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà General dataàDefine allowed material type forBOM header

Click

Follow the below steps to create new entries.

1. Click

Update required and optional fields:

Field Name Description ValueBOM Usage ### BOM usage according

to the application1 for productionBOM

Material typeheader

Header Material typeto which BOMcreation has to berestricted

Enter ROH

Allowed Select the symbolindicator to mentionallowed or not allowed

Select Negativesymbol toRESTRICT BOMcreation.

### Generic entry “*” can be made instead of a specific BOMusage. This indicates, it is applicable to all possible BOMusages.

2. Click Save .


When a new bill of material is created, the system checks thematerial type as follows:

§ Non-generic entries are checked first. The generic entriesare checked afterwards.

Error message will be displayed when creating BOM for RAWmaterial.

3.4 Define BOM Status

BACKGROUND

This configuration setting enables to define BOM status.

BOM status is used to define whether the BOM can be used byany application area or not.

Example: -

Ø In the costing areas in a company, the BOM is explodedaccording to the application. While defining the BOMstatus, usage in costing area will be defined.

Ø In MRP, the following indicators are checked directly fromthe definition of the BOM status:

- Explosion in MRP

- Released for orders

MRP only reads BOMs whose BOM status has at least one ofthese indicators.

BOM status defines whether

The BOM is active or inactive.

SCENARIO

BOM need to be created for certain for product whose BOMcan be finalized only after some trial and error.

While it is in preparation it is required not to be used by anyapplication. Status “In preparation” has to be created.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà General dataàDefine BOM status

1. Click

…..continuation of the above screen’s right side balanceportion

2. Click

3. Enter usage value. E.g. 6.

4. Leave all the check box as EMPTY.

5. Mention description as “In preparation”

6. Click Save .


BOM with status 6 can not be used for any application.

3.5 Define Item Category

BACKGROUND

This configuration setting enables to define item category.

The item category defines the attributes and functions of aBOM item. It controls field and screen selection for detailscreens in BOM maintenance.

BOM can contain different type of items related tomanufacture the finished product. There are

Ø Pipeline items – i.e. items which are receivedthrough a pipeline from supplier not related toinventory

Ø Stock items – i.e. materials are always issued fromstock which are relate to inventory

Ø Document item – i.e. Documents are referred in theBOM as a item trough the Document ManagementSystem (DMS)

Ø Text item – i.e. brief note about the material usagecan be maintained as a Text item. This will beuseful in a long BOM to indicate any specificassembly.

The above different items are defined through item category inthe BOM.

SCENARIO

Define item category to meet the situation as per the belowexample.

Example: - An Item code may be defined as a normal item inthe material master. The same item code for one specific BOMhas to be treated as a phantom material.

In such a situation, item category inside the item detail of theBOM will be mentioned as a phantom assembly. It is nowapplicable only to this BOM.

Let’s look at the standard setting for item category.

Item categories defined by SAP will be sufficient in most of thecases. If required, any new item category can be created.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà Item dataàDefine item category

1. Click

2. click

3. Update the following fields

Field Name DescriptionItem category Desired item category to be

mentioned in the BOMInv.Mgmt Relevant to Inventory

managementTxtItem It is text itemVsl Variable size itemDocument Item To mention DocumentCls Item To mention as Class item,

used in Variant configurationPM Str To mention as PM structure

elementIntraM To mention Intra Material

normally used in MasterRecipe-PPPI

+/- sign Negative value allowed in theBOM or not? This is requiredto indicate the by product.

SubI To indicate sub items aresupported.

Item Ctrl Sequence of Item detailscreen.

4. Select check boxes according to the businessrequirement

5. Mention Item category Text

6. Click Save .


While creating the BOM, required item category may beselected.

3.6 Define Allowed item type for BOM Item

BACKGROUND

This configuration setting enables to control the item typewhich can be entered as a component in the BOM.

Restriction to BOM item level can be done.

Example: - It may be required NOT to allow any FinishedGoods material type (FERT) to be a member of the BOM.

SCENARIO

It is required to restrict FERT material to be the member of theBOM.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà Item dataàDefine allowed material type for BOMitems

1. Click

2. Click

3. Update the following fields

Field Name DescriptionBOM usage BOM usage to define the

application areaMat tpe header Header material type to which

this restriction is to beapplicable

Material type BOMitem

Item type inside the BOM tobe restricted.

Allowed + sign to permit and –signNOT to permit

4. Click Save .


While creating the BOM, only allowed component type in thissetting are allowed to be a member of the BOM item.

3.7 Define Explosion types

BACKGROUND

This configuration setting enables to define how thecomponent in Bill Of Material is to be exploded duringprocessing.

This configuration setting governs BOM Component

• To be considered for planning or not

• To be considered in Long Term Planning or not

• Phantom assembly is to be planned or not

• Direct production should be activated or not

SCENARIO

For Long term planning, by default all the BOM items areconsidered.

If there are more items in a BOM and it is required to planonly very specific items in the LTP.

Then at BOM level against the item, LTP off indicator can beset. Now during LTP run, only relevant items are planned inLTP and all items are planned in MRP run.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà Item dataàDefine Explosion types.

1. Click


2. Click

3. Update the following fieldsField Name DescriptionExplosion type BOM Explosion type, free

entry.Description Description of the Explosion

type key.

Phan.off Phantom assembly is notapplicable to this item if thisindicator is set.

Plng off Material components are notplanned till the Sales order iscreated to this BOM item if thisindicator is set

DP Off Direct production functions areswitched off if this indicator isset.

LTP Off This will exclude the item inLTP calculation if this indicatoris set.

Indi/Coll It is to specify, whether togroup the dependantrequirement together or not

4. Maintain the entries in the check box as per therequirement

5. Click Save


BOM Item level explosion type can be defined. Key definedhere will appear in the screen to select.

3.8 Define Order of Priority

BACKGROUND

This configuration setting enables to define order of priority forBill Of Material to be selected during MRP and Production orprocess order creation.

Different Bill Of Material can be created for

• Production

• Costing

• Engg / Design

Selection priority must be defined to pickup the right Bill OfMaterial to the right application.

Link between this configuration and Master Data isestablished as below:-

• Selection priority will be defined through selection id.

• Selection id will have the sequence of BOM usage.

• BOM usage will be mentioned in the BOM

• Selection id of BOM will be mentioned in the order typeand MRP plant Parameter.

SCENARIO

There are more than one BOM (BOM usage) They are

1 for Production,

2 for Engg/Design

3 for Costing.

It is required to define the order of selection for BOM.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà Alternative determinationàDefine order of priorityfor BOM usage.

1. Click

Click to create additional order of priority for BOMusage.

2. Update the Following fieldsField DescriptionSelection Id Selection ID numeric

number to be entered.Selection Priority With in this selection

ID, priority to bementioned

BOM usage With in this selectionID and Priority,relevant BOM usage to

be selected.

3. Click Save .


During MRP run, production order or process order creationBOM selected according to this selection id priority.

3.9 Define Application

BACKGROUND

This configuration setting enables to define BOM Application.

BOM application controls use of BOM in a specific area.

Areas like MRP run, cost estimate calculation etc.. will use theBOM of its own respective BOM application.

SCENARIO

BOM display at multiple levels (transaction code CS12) can bedone for different BOM application. It is required to displayonly the costing BOM to certain users. Separate BOMapplication to be created to display the BOM related only tocosting.

Note: - BOM with usage for costing should be available. i.e.with the right usage for costing.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà Alternative determinationàDefine Applications

1. Click

To view the details, select the line and click

2. Update the Following fieldsField Description

BOM Application Enter any four digit BOMapplication area

Description Enter descriptionSelectin ID Selection ID through which

BOM selectedAlternative Det.Multi.BOM To select for alternative BOM

if multiple BOM is available.Tick this check box

Production Version If there is a productionversion, that is used as aselection criteria.

MRP explosion Leave BlankRel planned orders Leave BlankRelease costing Tick this check boxOther check boxes Leave Blank

3. Click Save .


When displaying the BOM through transaction code CS12,Right BOM usage will be displayed according to the settingsmaintained here. In this example, with BOM application, onlythe costing BOM will be displayed.

Press F4 in BOM application, where all the available settingwill be displayed.

3.10 Define Alternative Determination forMultiple BOM

BACKGROUND

This configuration setting enables to define automaticselection of right Bill Of Material during MRP and productionorder or process order creation, when there are more than oneBill Of Material to a material.

SCENARIO

Specific alternative BOM for some materials are to be explodedduring the MRP and other production order process forspecific duration.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà Alternative determinationàDefine alternativedetermination for multiple BOM.

1. Click


2. Update the Following fieldsField DescriptionMaterial Enter material code number

to which alternate BOM is tobe exploded

Plant Plant where it is applicableBOM Usg BOM usageValid From From date of BOM explosionAlt BOM Alternate BOM number which

is to be exploded.

3. Click Save .


Right BOM according to the setting here will be explodedduring MRP and Production processing.

3.11 Alternative determination in relatedapplication Area

BACKGROUND

Similar to the above alternate defining in production area, forother areas like Inventory, MRP, Costing, Sales andDistribution and Plant Maintenance can be maintained.

Only the menu path is given here and the rest of the settingsare similar to above.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà Alternative determinationàAlternatedetermination in related application area

àDefine alternate determination for inventoryàProductionàMRPàCostingàSales and distribution andàPlant maintenance

3.12 Define User-specific setting

BACKGROUND

This configuration setting enables to configure the parametersspecific to the user.

Following parameters

Item category

Item increment

BOM Reporting specification are can be set for a specificuser.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàBill ofmaterialsà Define user-specific settings

Click

To view more details, select the required row and click

Click to create new entries

Select the entries and tick the check box as shown above.

Field name Field value and descriptionUser Name of the user to whom the

default settings are to bedone.

Item increment While creating the BOM,incremental number to bedisplayed.

Mat. Item cat. Item category to be displayedby default.While using the where used

list query, this check box inthe selection box will appearas ticked by default.While using the where usedlist query, this check box inthe selection box will appearas ticked by default.

Click


User SAPUSER when creating the BOM, this default settingwill appear. This will help to reduce BOM creation time.

4. Work Center

Machines may be referred as work center. It is defined as theplace where operations are carried out.

Apart from machine, group of persons (e.g. in maintenancedepartment, certain group of people may be employed for anymachinery movements etc.) may be treated as a labor workcenter.

Data in work center used for

Ø Scheduling – start and end of operation

Ø Costing – Cost incurred during production

Ø Capacity planning - to plan the required capacity

Let’s see the configuration related to Work center.

4.1 Define Work center Category

BACKGROUND

This configuration setting enables to define work centercategory.

Work center category is the major classification of work centerby SAP. E.g. Machine, processing unit, labor are defined as adifferent work center category.

Work center category controls the field selection inside thework center.

SCENARIO

Create a work center category to mention skilled labor workcenter category.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà General Data àDefine work center category.

1. Click

2. Click

3. Update the Following fieldsField DescriptionCat Capacity category. Any new

value may be entered. E.g.ZLAB

Description Description of the desiredcapacity category. E.g. SkilledLabour category

Field Selection Contains the fields required tothis capacity category. Enterstandard SAP value accordingto the capacity category. E.g.0001

Screen sequence Sequence of tab screen to beappeared in the work centermaster data. Enter thestandard SAP value. E.g. 0001

4. Click Enter

5. Select Created capacity category

6. Double Click

7. Click

8. Enter Application – Area in SAP where this work centercategory can be used. E.g. P – Routing; C - MasterRecipe; Q - Quality task list etc.

9. Note:- If this work center category is to be applicable toall, maintain all the entry in this application field.

10. Click .


When creating the work center for skilled labor, work centercategory is to be mentioned as it is a mandatory entry.

4.2 Define Field Selection

BACKGROUND

This configuration setting enables to make the field in workcenter master data as

Mandatory

Optional

Highlight

Hide

Field selection will be used to make certain field as mandatoryentry or to hide certain fields during creation of work centermaster data.

SCENARIO

Make field person responsible for work center category 0007as mandatory field.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà General Data àDefine field selection.

1. Click

2. Double click Basic data

3. Double click Person responsible

4. Click Field selection Req. radio button for the requiredwork center category. Contents column indicate the workcenter category.

Note:- From this screen it may be noted that personresponsible entry is mandatory for work center category0001,0002 and 0008

5. Click to add more entry.

6. Enter content 0007 or any work center category.

7. Click radio button Req.

8. Click

9. Click


When work center with category 0007 is created, personresponsible field become mandatory.

Note:- Field selection procedure is same for Routing as well.

4.3 Define Task List usage

BACKGROUND

This configuration setting enables to define the task list usageto the work center.

Usage of work center specific to the task list (i.e. only in themaster recipe or Routing) can be defined to restrict its usage.

SCENARIO

Define the task list usage to the work center category 0007 tobe used in Routing and in Reference Operations set only.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà General Data àDefine task list usage.

1. Click

2. Select

3. Double click Task list type

4. Click


Task List type N for Routing and S forReference Operation set

6. Click Save .


When creating Work center usage is to be mentioned as 001.

Once this is maintained, then it will not be possible to use thisWork center in Master Recipe or in Rate routing.

4.4 Define Parameters

BACKGROUND

This configuration setting enables to define Parameter(activities) for formula.

Parameter is one of the required settings to calculate theconversion cost incurred in the Work center duringmanufacturing.

Work center while in use can consume

• Power

• Labour

• Setup time

• Depreciation

• Steam etc.

The above costs incurred during conversion will be capturedthrough the activity. Parameter is the structure to capture thisactivity.

This will be assigned to the standard value key. Standardvalue key will be assigned in the work center.

SCENARIO

Create a Parameter. Note:- Standard SAP setting is sufficient.Let us discuss the creation of new parameter.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà General Data àStandard ValueàDefine Parameters.

1. Click

2. Click

3. Update the Following fieldsField DescriptionParameter Parameter to hold the value.

Any alphanumeric six digitmay be entered. E.g. LABOUR

Origin Place where from the value isto be taken. E.g. To indicatevalue to be taken from tasklist maintain 2 in this field.

Short key word Short descriptionKey work Key word to identifyDimension Dimension of the parameter.

E.g. Any thing related toDuration may have TIME asdimension.

Standard Value Unit Unit of this parameter. E.g.Time dimension may haveunit as MIN.

Note: - If any parameter for which there is no unit, it may bementioned as no unit.

4. Click Save .


Link between the parameter and the master data is as below.

a. This parameter will be assigned to the standard valuekey.

b. Standard value key will be attached with the work center.

c. Work center will be attached in the task list. I.e. in therouting or in the master recipe.

d. Standard value (i.e. duration of labour hours required)will be maintained in the task list as a master data.

4.5 Define Standard Value

BACKGROUND

This configuration setting enables to define the standard valuekey.

Standard value key is very essential to capture the costincurred in the work center.

Standard value key will contain the activities. One standardvalue key can contain up to six activities. Each activity refersto the cost.

Example:-

• Production cost

• Set up cost

• Labour cost

• Quality Cost

• Power cost

• Steam cost

One work center can have only one standard value key.

SCENARIO

Create a standard value key to have the activities of setup,machine, labor, and over head.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà General Data àStandard ValueàDefine standardvalue key.

1. Click

2. Click

3. Update the Following fieldsField DescriptionStandard value key Enter any alpha numeric to

indicate standard value key.E.g. STD1

Description Maintain standard value keydescription. E.g.setup/machine/labor/Power

Parameter Maintain the parameters. Upto six parameters can bemaintained.Tick this check box togenerate formula.

4. Click Save .


When creating the work center, standard value key STD1 to bementioned.

4.6 Determine Person Responsible

BACKGROUND

This configuration setting enables to define the personresponsible for work center.

Every work center will have a responsible person to schedulethe work load to that machine and to monitor the workinghours and output from that work center.

This field can be used for reporting purpose also.

SCENARIO

Create a work center responsible person.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà General Data àDetermine person responsible

Click

Click

Update the Following fieldsField DescriptionPlant Name of the plant e.g. IND6Person Responsible Three digit alpha numeric

entry to mention theresponsible person to thework center. E.g. INP

Person responsible description Detailed description of theperson responsible. E.g. In-charge Processing Unit

Click Save .


When creating the work center, person responsible has to beentered.

4.7 Define Control Key

BACKGROUND

This configuration setting enables to define control key.

Control key governs

• Scheduling of operation

• Cost calculation for an operation

• Capacity calculation for an operation

• Confirmation for an operation

Control key is mapped with the work center in the task list(i.e. in the routing and in the master recipe).

SCENARIO

Create a control key with confirmation as mandatory and itshould calculate the cost and capacity, it should also schedulethe operation.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà Routing Dataà Define control key

1. Click

2. Click

3. Update the Following fieldsField DescriptionControl Key Enter any alphanumeric four digit

key. E.g. YP01Description Maintain description of this control

key. E.g.Sch/Cost/Capreq/Confreq/AutoGR

Indicators Tick the check box as shown abovein the screen.Tick in the Check box will performthe respective function to theoperation / phase which is havingthis control key.

4. Click Save .

5. Click to maintain any long text to thiscontrol key.

6. Maintain the long text.

7. Click Save .

8. Click

9. Click if you get the Other language screen.

10. Click Save .


Link between control key and Transaction:-

Control key is attached in the task list with work centerfor each operation

While performing order creation, confirmation, MRP runsystem will behave according to this configurationsetting.

5. Capacity Planning

5.1 Define Capacity Category

BACKGROUND

This configuration setting enables to define the capacitycategory.

Capacity category will differentiate the type of capacity used inthe work center.

Capacities can be

• Machine

• Labor

• Processing unit

Capacity category and capacity details are assigned to thework center.

SCENARIO

Create a capacity category.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà Capacity Planningà Define capacity category

1. Click

2. Click

3. Update the Following fieldsField DescriptionCategory Capacity category. E.g 001Description Description of capacity

category e.g. machine

4. Click Save .


Capacity category is to be mentioned in the capacity headerdetail in the work center.

5.2 Determine Capacity Planner

BACKGROUND

This configuration setting enables to define the capacityplanner.

Capacity planner is the person who is responsible to plan andschedule the specified capacity.

SCENARIO

Create a capacity planner.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà Capacity Planningà Determine capacity planner

1. Click

2. Click


Planner Enter capacity planner. E.g.IN6

Description Enter capacity plannerdescription. E.g. Processingunit plan

4. Click Save .


Capacity planner is to be mentioned in the capacity headerdetail in the work center.

5.3 Define Shift Sequence

BACKGROUND

This configuration setting enables to define shift sequence.

Shift sequence is used to define the specific working pattern.I.e. weekly holidays, number of shift and working hours ofeach shift.

Work center capacity is calculated from its working hoursdefined in the capacity header details of the work center.

There are mainly three ways to define capacity for each workcenter.

• Normal capacity

• Available Interval capacity

• Interval and shifts

Normal capacity is defined through the working hrs and breakin the capacity header

Available interval capacity is the capacity available for anyspecific duration; it is defined at the capacity header detail

Interval and shifts is defining the shifts in which the machineor industry works.

SCENARIO

Create a shift sequence with two shifts a day and Thursdayand Friday as weekly holiday.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà Capacity Planningà Available capacityà Define shiftsequence

1. Click

2. Click


Grouping Enter shifting grouping. E.g.SG

Description Enter description E.g. SpecialGrouping

4. Click two times

5. Select the Grouping

6. Double Click

7. Click

8. Update the Following fieldsField DescriptionBreak Enter the Break name. E.g.

IN6BBreak Number Enter the break number E.g. 1Description Description of break. E.g.

First shift breakStart Break start timeEnd Break end time

9. Click (Complete all the break required as explainedabove)

10. Click

11. Select the break 1 line

12. Double click

13. Click

14. Update the Following fieldsField DescriptionShift Enter shift name. E.g.1SHFShift text Enter shift definition. E.g.

First shiftStart date Starting date of the shiftEnd date End date of the shiftStart time Starting time of the shiftEnd Time End time of the shiftBreak Enter the Break schedule. E.g.

IND6

15. Click

16. Select the 1SHT line

17. Double click

18. Click

19. Update the Following fieldsField DescriptionSequence Enter the sequence No. E.g.

01Shift No. Shift number in the sequence.

E.g. 1Description Description of the shift

sequence. E.g. Two shift perday

Day1 to Day 7 Maintain the desired shiftdefinition the day to follow.E.g. 1SHT and 2SHT in alldays except Thursday andFriday.

20. Click

21. Click Save .


This shift sequence can be maintained as an interval ofavailable capacity.

This can be maintained in the work center capacity headerdetail.

Once this is assigned, working days and hours to this workcenter will be as per this shift sequence.

5.4 Define Formula Parameters for Work centers

BACKGROUND

This configuration setting enables to define the parameter forthe formula.

Formulas are to be defined to calculate

Cost

Capacity requirements

Schedule the operation

Formula parameter will be used in the formulas. Formulas areused in the work center capacity view, scheduling view andcosting view to

Calculate capacity

Schedule the operation

Calculate the activity cost.

Note:-

This configuration is similar to defining the parameterexplained above. However it is reproduced for your quickreference here also.

SCENARIO

Define formula parameter.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà Capacity Planningà Work center formulasà Defineformula parameter for work center

1. Click

2. Click

3. Update the Following fieldsField DescriptionParameter Parameter to hold the value.

Any alphanumeric six digitmay be entered. E.g. LABOUR

Origin Place where from the value isto be taken. E.g. To indicatevalue to be taken from tasklist maintain 2 in this field.

Short key word Short descriptionKey work Key word to identifyDimension Dimension of the parameter.

E.g. Any thing related toDuration may have TIME asdimension.

Standard Value Unit Unit of this parameter. E.g.

Time dimension may haveunit as MIN.

Note: - If any parameter for which there is no unit, it may bementioned as no unit.

4. Click Save .


Formula parameter defined here will be used in the formulas.

5.5 Define Formula for Work centers

BACKGROUND

This configuration setting enables to define the formulas.

Formulas are used in

• Calculate capacity requirement

• Schedule the start and end of the operation

• Calculate the cost

Formulas will be assigned in the work center capacity view,scheduling view and in costing view.

SCENARIO

Create the formula to calculate the machining time.

Note: - standard formula given by SAP will meet manyrequirements. Let’s discuss the creation of formula.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà Capacity Planningà Work center formulasà Defineformula parameter for work center

1. Click

2. Click

3. Update the Following fieldsField DescriptionFormula Key Enter formula key. E.g.

SAP002Description of the formula key Enter descriptionFormula Maintain the formula. Mostly

SAP defined formula would besufficient. Let us discuss theSAP Standard formula andunderstand it. Any newformula can be created similarto it.

4. Parameter defined here are

SAP_02 Machine value from routingSAP_09 Operation quantity- value from routing field

operation qty.SAP_08 Base Quantity – value from routing field base

quantitySAP_11 Operation split – value from routing field split

Above formula defined to calculate the machining time,

Machine time * Operation Quantity / Base quantity /Operation Split

5. Indicators:-

Field name Field description and valueTick in this check boxindicates, this formula isgenerated in the system.Tick in this check boxindicates, this formula can be

used to calculate cost.Tick in this check boxindicates, this formula can beused to calculate capacityrequirements in MRP.Tick in this check boxindicates, this formula can beused to calculate PRTrequirements.Tick in this check boxindicates, this formula can beused for schedulingoperations.


Formula is used in work center capacity, scheduling andcosting views.

5.6 Define Factory calendar

BACKGROUND

This configuration setting enables to define the Factorycalendar.

Factory calendar will contain the entire working day andholiday details for a specific plant.

Factory calendar will be attached to the capacity header.Factory calendar will be referred while scheduling theoperations.

SCENARIO

Define factory calendar for plant IND6.

INSTRUCTIONS

Follow the Menu Path: IMGàGeneral settings à MaintainCalendar

Note: - Factory calendar will be defined directly in the client. Itwill not be captured and transported through TransportManagement.

Click

First Holiday calendar has to be maintained. There are twoholiday calendar,

1. Public holidays2. Specific Holiday calendar

Steps involved in Calendar maintenance are

• Create public holidays

• Create Holiday calendar and assign the public holiday inthe holiday calendar

• Create Factory calendar and assign the Holiday calendarin the factory calendar.

Then the holiday calendar will be assigned to the factoryCalendar.

Let’s now maintain public holidays.

Select Radio button Public holidays

Click

Click

Select

Click

Click

Click

Create all public holiday by repeating the above explainedsteps.

Click

Select

Click

Click

Enter calendar id. E.g. I6 to indicate it is for IND6 Plant

Enter description of the calendar. E.g. Holiday Calendar forIND6 plant.

Enter valid from year and To year. E.g. From 2005 to 2025

Click

Select the required public holidays to be assigned to theholiday calendar.

Click

Click

Note: - Whenever the calendar maintenance are saved, systemwill give the message as shown above.

Click

Note: - To delete the assignment select the required holidayand click

Click two times

Click

Click

Click

Maintain the entry as above.

Click

Click

Click three times to reach the main IMG menu.

5.7 Define Default Capacity

BACKGROUND

This configuration setting enables to define the defaultcapacity category for a plant.

By defining the default capacity, for work center and resource,if the capacity is not defined, system will consider this defaultcapacity detail.

SCENARIO

Define default capacity category for plant IND6.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà Capacity Planningà Define default capacity

Click

Update the Following fieldsField DescriptionPlant Enter the name of the plan.

E.g. IND6Category Capacity category. E.g. 001

Click

Maintain the details as shown above.

Note: - this is the master data can be maintained inside theeach resource or work center in capacity header details.

5.8 Define Work center screen sequence

BACKGROUND

This configuration setting enables to define the screensequence for work center.

Screen sequence setting controls the sequence of appearanceof screen while creating the work center master data.

Work center contains the following important tab screens

• Basic view

• Default values

• Capacity

• Scheduling

• Costing

SCENARIO

Create a different screen sequence for work center categoryZLAB.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasic dataàWorkcenterà Setup work center screen sequence

1. Click

2. Enter work center category ZLAB

3. Click

Field DescriptionNo Sequence number in which

tab screens are to bedisplayed

Man Mandatory. Entry to be madein this tab screen if this checkbox is ticked.

Note: - Normally this setting is not at all disturbed, exceptmaking some tab screen as mandatory.

Click


While creating the work center the sequence of Tab screen willappear as per the configuration setting done here.

6. Routing

Routing explains how the product is to be manufactured. Itmay be compared to a process sheet in the conventionalsystem. It contains

Ø Operations to be carried out during manufacturing

Ø Use of material during production

Ø Use of work centers

Ø Quality checks to be carried out during production

6.1 Define Standard value description inoperation over view

BACKGROUND

This configuration setting enables to define a key to hold thestandard text to be used in the routing operation.

If any common operation description is to be referred in thetask list (routing or in the master recipe), a standard keycontaining the text can be used.

SCENARIO

Create a standard value key text for Routing.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasicdataàRoutingà Control dataà Define standard valuedescription in operation over view

1. Click

2. Enter task list type N for routing

3. Click

4. Click

5. Update the Following fieldsField DescriptionLanguage EN to denote English

1st SV Txt upto 6th SVTxtvalue

First standard value text up to6th standard value text value.Text entered will appear in therouting operation.

6. Click Save .


While confirming the operation these texts will appear againstthe activity type.

6.2 Define Routing Status

BACKGROUND

This configuration setting enables to define the routing status.

Routing status helps to use the routing only for specifiedpurpose. I.e. Routing use can be restricted only for costingpurpose till the costing trial is completed.

Routing status can be

In Process

Released for costing only

Released for production

Selection of routing during production order or process ordercreation is based on the routing selection.

Routing status has to be maintained in the routing header.

SCENARIO

Create a routing status.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasicdataàRoutingà General dataà Define routing statuses

1. Click

2. Click

3. Update the Following fieldsField DescriptionStatus number Enter numeric valueDescription Description of the status

number. E.g. Under creation,or only for costing.

RelInd Released Indicator, when thisis set, routing will be used inOrders.

Costing Indicates, task list is releasedfor costing.

Consistency Chk Consistency check is carryoutautomatically when saving.

4. Click Save .


While creating the routing status is maintained.

6.3 Define Task List usage

BACKGROUND

This configuration setting enables to define task list usage.

Task list usage defines the specific purpose of routing.

There are four important usage of Routing.

• Production usage

• Costing only

• Sales and Distribution

• Universal ( all purpose)

It is possible to control the usage of routing according to itsusage.

SCENARIO

Define routing usage for multi purpose usage.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasicdataàRoutingà General dataà Define routing usage

1. Click

2. Click

3. Update the Following fieldsField DescriptionUsage Enter the usage number. Any

numeric number. E.g. 1Description Description of the usage. E.g.

Universal

4. Click Save .


Usage of Routing has to be mentioned while creating routing

6.4 Define Reduction Strategy

BACKGROUND

This configuration setting enables to define reduction strategy.

Reduction strategy defines the sequence of compressing thetime or duration to meet the production dates.

Reduction strategy can reduce the following times which areinvolved in scheduling

• Queue time

• Move time

• Over lapping

• Split

Reduction strategy will be employed when the calculated leadtime in scheduling is longer than the time between the basicdates (required start date and finish date is the basic date),the system will carry out reduction measures to reduce thelead time.

Reduction is carried out step by step. After each reductionmeasure, the system checks whether the calculated dates arewithin the basic dates. If this is the case, no further reductionmeasures are carried out.

SCENARIO

Create a reduction strategy.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasicdataàRoutingà Operation dataà Define reduction strategy

1. Click

2. Click

3. Update the Following fieldsField DescriptionPlant Enter the plant to which

reduction strategy is to becreated. E.g. IND6

Reduction strategy key Any number to identify thereduction strategy. E.g. 1

Reduction strategy Description of Reductionstrategy. E.g. Over alreduction for IND6

4. Click

5. Select the Reduction strategy key entered above

6. Double click

7. Click

8. Update the Following fieldsField DescriptionRe Reduction Level. E.g. 1Reduction Queue Enter the % of reduction in

queue timeTransport Tick the check box to indicate

the reduction in move timeOverlap Tick the check box to indicate

the reduction in move timeSplit Tick the check box to indicate

the reduction in move time

Note: - Repeat the above step as different level as shownbelow.

9. Click Save .


This reduction strategy can be maintained in the Routing.

6.5 Define User Fields

BACKGROUND

This configuration setting enables to define user fields.

User field can be used in the operation heading in the task listto define your own reference data.

Maximum of six fields can be defined through the user field.

SCENARIO

Create user defined field.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasicdataàRoutingà Operation dataà Define user fields

1. Click

2. Click

3. Update the Following fieldsField DescriptionField Key Enter the name of the field.

E.g. OPERDTDescription of the field key Enter the description. E.g.

Operation detail user field

Maintain the text field as shown above


User field may be maintained at Routing operation headerlevel. Below screen shows the user field, where the details ofcreated by and other details can be maintained.

6.6 Define Routing Selection Automatic

BACKGROUND

This configuration setting enables to configure the automaticselection of routing (Task list).

Task list has to be selected automatically during

• Production order creation (Routing)• Process order creation (Master recipe)• Cost estimate calculation• MRP run

Routing is essential to

• Calculate the conversion cost

• Calculate the capacity requirements

• Schedule the operation

• To schedule the material at right time in MRP

SCENARIO

Define Automatic routing selection.

INSTRUCTIONS

Follow the Menu Path: IMGàProductionàBasicdataàRoutingà Routing selectionà Select automatically

1. Click

2. Click

3. Update the Following fields

Field DescriptionID Selection id. E.g. 01Selection Priority Priority of selection in this ID.

E.g. enter from 1,2 …Task List type Mention the task list type. E.g.

N for routing, 2 for masterrecipe

Usage Enter the Usage of this tasklist. E.g. 1

Status Enter the status of this tasklist. E.g. 4

Note: - Repeat the above with the same id as shown below.


In the order type dependant parameter and MRP plantparameter configuration

Selection id 01 will be mentioned.

While performing the transaction (creation of process order orproduction order or MRP run), automatic selection of routingwill be performed in the following sequence:

• First system will search task list type routing as per thesequence 1

• System will search for routing with usage 1

• System will search for routing with status 4

If the above search fails, system will go to the next sequence inthe same selection id. I.e. sequence no. 2 in our above shownscreen shot.

• system will search task list type routing as per thesequence 2

• System will search for routing with usage 1

• System will search for routing with status 2

7. Summary:-

We have discussed the Master data related configurationsettings.

You must be able to configure master data in SAP according tothe business requirement in the following areas

Bill Of Material

Work center

Routing

Friends, please note that the most of the configuration settingsrelated to master data are common to manufacturing types

Discrete

PPPI

Repetitive

The terminology only differs in the various processes.

For E.g. Routing is called as master recipe in PP-PI and inrepetitive routing is called as rate routing.

Discrete PPPI Repetitive

Routing Master Recipe Rate Routing

Work center Resource Production line