Minimum Configuration Required for Routings

Allowed Material Types for the Task List Here you can configure the allowed Material Types for the task List such as Routings, Rate Routings, Reference Operation sets, Rate Reference operation sets, Recipes etc. SAP nevertheless has already preconfigrued with standard material types and Routing types, though if you want to add more material types to the list you can do so. Transaction code - OP50 : The following are pre-configured by SAP, though you can add more.

Task List type N N S S R R M M

Description Routing Routing Reference Operation Sets Reference Operation Sets Rate Routing Rate Routing Reference Rate Routing Reference Rate Routing

Material Type FERT HALB FERT HALB FERT HALB FERT HALB

Description Finished Products Semi finished Products Finished Products Semi finished Products Finished Products Semi finished Products Finished Products Semi finished Products

User Defined Fields You can define upto 18 different fields - 6 Text fields, 3 Qty Fields, 3 Value Fields, 3 Date fields, 1 check box and 2 indicators. This you can use for defining the following: Parameters in Scheduling, Capacity, Costing Formulas (Standard Formulas) Production Process related or Operation related information Any other user defined field

Transaction code for configuration - OPEC You have to define these user defined fields in a fields set called a Field Key.

Routing Selection -

Routing selection is configured for automatic selection of Routings in the Production orders. Against every Selection ID that you create, you would be declaring the proirity of selection of Task list (Routings)

Transaction code is OPEB. SAP has already pre-configured the automatic Selection. Every Selection procedure has a selection ID >>> Selection ID has Priorities >>> Selection ID has Task List Usage and Status

Selection Selection Task List ID Priority Selected 01 01 01 01 1 2 3 4 N N R R

Usage 1 - Production 1 - Production 1 - Production 1 - Production

Status 4 2 4 4

Status Description Released (general) Released (order) Released (general) Released (order)

What the table means This above configuration means that the production order where the selection id is used should first choose the Routings task list which has usage 1 and status 4, if this Routing is not found for the production order material then as second priority option, the system should try to find the Routing task list of usage 1 and status 1 if found, if this Routing is also not found, then the system as a third priority option should try to find out a Reference operation set whose usage is 1 and status is 4 and it has a header material (in question) allocated to it already and if this is also not found then the system has a last option to search for a reference operation set whose usage is 1 and status is 1. Ultimately if SAP cannot find any task list for the order type being created, it will either Abort or continue creation of Production oeder based on the configuration. Use of Selection ID This "Selection ID" is assigned to the "Production order type" in the order type dependent parameters configuration, to inform the Production order on selection priorities of Routings.

PRT Configuration -Define PRT Control Keys -

The PRT control key determines whether PRTs that are allocated to a task list or an order are included in the following business functions: a. b. c. d. Scheduling Costing Printing production orders Completion Confirmation

The path for this configuration is - Tcode SPRO >>> Production >>> Basic Data >>> Routing >>> Assignment of Production Resources/Tools >>> Define PRT Control Keys Define Formulas for PRT In PRT maintenance, formulas are used to calculate the usage value and the quantity required of a PRT. . Note: Formulas are also used in capacity planning, scheduling and costing to calculate capacity requirements, lead times and costs. Standard SAP provided formulas are: SAPF01 SAPF02 : PRT: Quantity : PRT: Usage value .

The path for this configuration is Tcode SPRO >>> 1st - Production >>> Basic Data >>> Routing >>> Assignment of Production Resources/Tools >>> Define Formula Parameter (or directly use T-Code OP52) 2nd - Production >>> Basic Data >>> Routing >>> Assignment of Production Resources/Tools >>> Define Formula Parameter (or directly use T-Code OP55) Routings Routings define the production activities and sequence in which these production activities are to be carried out in order to produce a certain material. Routings are used in SAP PP/REM. The operations in a Routings are assigned to work centers, PRT, inspection characteristics, BOM components and Trigger points.

It defines the order in which the operations need to be processed so as to produce a material. Routings are task list and they are categorized as Routings, Rate routings, Reference operation sets, Reference Rate Routing. Example Routing For Material M1 at Plant 0001 Material M1 at Plant 0001

Operation = 0010: Work center = WC1: Components-C1, C2, C3: PRT0001 Operation = 0020: Work center = WC2: Components- C3, C4: PRT0002: Operation = 0030: Work center = WC3: Components- C5, Operation = 0040: Work center = WC4: Components- C6,

Type of Routings

Routings are task list and they are categorized as Routings, Rate routings, Reference operation sets, Reference Rate Routing. 1.0 Routings A Routing is used for specifying the sequence of operations to be used for production, Routing is used in SAP PP. The operations in a Routings are assigned to work centers, PRT, inspection characteristics. You can create material specific Routings by creating the Routing for a material and plant combination. You can also create a Routing without specifying the material or the Group number and after creation the system will allocate a Routing Group number generate internally (you can also provide an external Routing number before creation in the selection screen). Once such a Routing is created you can allocate this routing to all the products which are manufactured with the same production processes and activities through the same set of work centers, production resource tools (if any) and Inspection characteristics (if any). After creation of such a Routing, you can recall the routing in the change mode through the Group number. Once you allocate such routing to many products, any change in the routing is also applicable to all the allocated material Routings. Transaction code to create, change, display Routings CA01, CA02, CA02 Task list type = N

2.0 Reference Operation sets If certain sets of operations are used frequently in many Routings, they can be created separately in transaction code CA11 {Change/Display: CA12/CA13). You can call such reference sets of operations in any Routing, to simplify the creation process of Routing. After calling a specific set of operations you need to unlock that set and make it free for use in the Routing under creation. Once you unlock that set in your Routing you would remove the link with the reference operation set. You can change these operations in the Routing under creation, once you unlock the reference set. You cannot assign a material to be produced to a reference operation set. It can have neither parallel nor alternative sequences. Task list type = S

3.0 Rate Routing A routing for whose operations the production quantity and a fixed duration has been defined. Thus the production rate is also defined. Rate routings are used when you plan on a quantity basis, for example in repetitive manufacturing. It can have parallel sequences. The transaction codes to create a Rate Routing are CA21 (Change/Display: CA22/CA23) Task list type = R

4.0 Reference Rate Routing Similar to the Reference Operation sets, the operation sets created as Reference rate Routing can be called in the creation of Rate Routing to reduce the efforts of creation. The transaction codes to create a Reference Rate Routing are CA31 (Change/Display: CA32/CA33). Task list type = M Operations of a Routing can be assigned with Each of these operations which are placed in an order of processing is assigned with:

Work center Each of the operations in a routing is assigned with a work center and this work center in turn has the activities that are assigned to it, specifying their consumption is logical when you carry out work their. The standard values or parameters that are assigned to the work center help in analyzing the capacities that would be consumed to manufacture a product, schedules (start times and finish times) and the costs that will be incurred. The work centers are assigned in the Routing operation overview screen. Note You can create an operation without a work center, but there would be no standard value activities resulting in no scheduling, no capacity allocations and no costing for such operations.

PRT Production resource tools Production resource tools can also be assigned to the operations specifying the use of tools such as jigs and fixtures (as an example) and that their consumption is logical when you carry out work at the operation. To assign PRT to the operation you need to create them first. Assignment of PRT is not a mandatory task.

Inspection Characteristics You can assign inspection characteristics to the operations specifying that you are going to carry out In-process production order inspection. To assign inspection characteristics to the operations you need to create quality inspection characteristics first and then assign to the Routings.

BOM components The Routing operations are assigned with BOM components so that:

a) Backflush Components which are marked as backflush are supposed to be issued automatically to the Production order at the time of Order confirmations. Thus all the components which are marked as backflush should be assigned to respective operations. b) Requirement date If components are allocated to an operation, the system can derive for you a requirement date of the component for the production order. This requirement date can help the materials management team and the shop floor operator to make the raw material available on the operation start date. Note - If component are not allocated to the operations, then the SAP automatically allocates all the BOM components to the first operation. This also means that all the backflush materials would be automatically issued when you confirm the first operation. And this also means that all the raw materials would be available for production on the start date of the first operation.

Sequence of operations: Standard Sequence Default Sequence - The Operations in a routings are processed one after the other unless otherwise you add an alternate sequence of operations or parallel sequence of operations. Alternate Sequence - In an alternate sequence you are replacing the certain operations with a different set of operation/s. Lot sizes can only govern the selection of the alternate route, this lot size range is different than that entered in the Routing header though they should overlap and should not be vaguely different. Parallel Sequence - If in the production process, certain operations are to be processed along with each other or simultaneously then you need to introduce parallel sequences for those set of operations. The operations introduced in the parallel sequence and the operations in the standard sequence might have different lead time, thus to align the standard sequence with the parallel sequence we need to introduce floats at the start or end of the standard or parallel sequence. To this purpose, you create an alignment key for the standard sequence and every parallel sequence.

Creating a Routing

Creating a Routing:

A Routings can be created as follows for all the Materials in a plant that are to be produced:

Enter the Following in the selection screen -

Material Code / Plant Enter the material code and the plant code for which you want to create the Routing. All the Materials in a plant that are to be produced need a Routing. Group Entering a Group Number is not mandatory, if you have not entered the Group Number, SAP will generate one for you after you press the save button for creation. Key Date The Key date that you would enter should be a date on which your work centers and cost center and BOM is valid. You should make sure of such information. And if you enter any date on which any one of them is not valid, you would end up with errors or warnings.

Enter the Following in the Routing header screen -

Group Counter A Group Counter is similar to BOM alternates. It defines the Routing alternates. A Group Counter 01 means that it is the first alternative routing. When you want to add one more

alternative to the group you can do so and the next routing alternate will be 02. It is also possible to use alpha numerical 2 characters value like AA, 2A. A Routing is always defined by the material number of the routing, the plant of the material, the group number and the groups counter number. Criteria to have multiple Routings for a material a) Due to the change in production process methods b) Use of different work centers. c) Changes in production methods or routes due to production lot sizes, i.e. production order quantities. d) Seasonal changes in production routes or production processes. e) Etc.

Usage It is a mandatory field and it defines the area where the Routing is going to be used. If a Routing is to be used only in the area of production, then you can pick a value = 1 and if it is to be used in plant maintenance then you will assign an usage = 4 (you can use usage = 4 when you are creating a maintenance plan task list)

Planner group This is a non Mandatory field. A Planner group field value identifies a group of planners responsible for maintaining the Routing. This is absolutely not mandatory and not required for entry unless and until you want to classify the routings through this key.

From Lot Size To Lot size In this field you can define a lot size range for which the Routing is applicable. Many a times the production routes or the production methods or the production processes change due to change in production quantities, thus to accommodate this you can enter a lot size range. When a lot size of production is not a factor to have multiple routings for a product, you can have one single lot size from 0 to 99,999,999. An Example on How Routing Lot Sizes are used

If you create a Material Routing with a Routing Group Counter 01, having a Lot size from 0 10000 and then if you create a production order for a quantity of 10001, this Routing will not be pulled in to the production order. On the other hand, if you create one more Material Routing with a Group Counter 02 for a lot size 10001 99999, then this Routing Counter 02 will be pulled in the above production order. Similarly if you create a Production order with order qty of 9000, the Routing with a Counter 01 will be used for production. Thus we can summarize that Routing Lot Sizes are one of the factors which make to create more than one Routings for the same material (through the use Routing Group Counters)

Lot Size UOM The Lot Size UOM is normally the Base UOM of the material for which you are creating the Routing. It is defaulted in the Routing from the material master.

Inspection points If you plan to use SAP QM In-Process Inspections with quality inspection planned at various Routing operations, then you have to identify an inspection points. In the case of In-Process Inspections, you can carry out quality inspections at an operations numerous number of times, i.e., for example, if you produce 20 out of 100 quantities of the order you can carry out a inspection recording, and similarly if you receive 5 more you can carry out inspection at that point of time for the same production order operation and if you receive the remaining 75 against the same order you can again carry out an operation inspection using an inspection point. An Inspection point defines the administrative data of inspection that would be carried out at a given point of time. SAP provides the following user defined fields that would clearly identify your inspection point (the following is just an example)

User Field Text Length 18 Text Length 10 No. Length 10 No. Length 3 Date Time

Fields actively in Use 1 5 4 2 3

Keyword Operator Inspected Quantity Shift Number Date Time

You should configure such a required combination for header data entry for each inspection (inspection point) and choose freely defined inspection points value 100 in the drop down. Inspection point definition if not entered here, is fetched from the plant level settings. Thus you can afford to forget an entry here if you have set at the plant level for use for the in-processinspection of all the products in the plant. Note I would not go through the pains of In-Process inspection as in-process-inspections do not govern usage decision on the material produced. SAP QM in-process inspections are only for information purpose. Therefore if you want to decide the usage of a material and at the same time record quality inspection results you can use inspection at Goods receipt. Therefore the following 2 fields also are not be important if you are not using in-process inspection. Partial Lot assignment This is also SAP QM related information used for in-process-inspection. You can have the partial lots generation methodology defined for each of the material in the Routing and if you want to use the default settings made for QM at the plant level in SAP QM Configuration then you can choose so. The partial lot assignment for each inspection point with batch creation or without batch creation seems logical choice for in-process inspection. Partial lot assignment during result recording is an optional tool. Dynamic Modification If you are planning to use SAP QM Dynamic Modification for in-process-inspection to tighten or reduce the inspection scope, then you have to choose a level at which it is carried out inspection lot or inspection characteristics level. The system evaluates the number and results of the last checks with this rule. From the inspection severity determined this way it lays down the inspection scope for the individual characteristics using the sampling procedure. Enter the Following in the Routing Operation screen -

When you press DETAIL OPERATIONS on the header screen, then you would reach the operations overview screen. Where you can enter the following: The Operation related data can be changed in the production order where it is used.

Operation number SAP provides a sequential operation number, but if you dont like this you can overwrite it with you own numbering scheme. Sub-operation Enter a sub-operation number if you have any. You cannot assign material components, production resources/tools or inspection characteristics to sub-operations, though you can assign all this to the superior operation. A sub-operation can be costed, but can only be scheduled relative to superior operation. You can cumulate standard values from sub-operations on the corresponding operation. A Sub-operation can be processed externally. Confirmations can be made at the sub-operation level. Note - Normally in SAP PP, I have seen people rarely using sub-operations.

Work Center Enter a work center number where the operation is going to be carried out. Once you enter the work center for the operation, the operations adopts the control key value, the standard text descriptions, the standard value key and the parameters inside them, the capacity generation formulas, the scheduling generation formulas and the costing requirement generation formulas. Though for every operation it is not mandatory to enter a work center. Note Identifying which operations are to be included in the Routing is very important and as a consultant you should decide, on various criteria such as machining time, bottleneck operation, costing relevancy, whether an operation should be included in the Routing. Control key Control keys are normally pulled in from the work center, if you have entered a default control key there. Control keys are really important keys in SAP PP. A control key governs the following controls for a production order Routing:

Whether a work center at an operation should be scheduled. Whether a work center at an operation should be subjected to cost derivations. Whether a work center at an operation should derive the capacity requirements. Whether a work center at an operation can have auto goods receipts posted from it. Such work centers are the last work centers in a sequence of operations laid in a routing or recipe. Whether a work center at an operation can be subjected to quality inspection through the use of quality inspection characteristics assigned in a quality inspection plan. Whether a work center at an operation is externally processed and not processed in house; in which case a purchase requisition will be created to send the process out for production, please note that if you are sending the process out for production, the purchase requisition is not created for any material code but it is created for the process description without the material code in the requisition. Whether a work center at an operation should be allowed to carry out confirmations and if confirmations are allowed whether these confirmations types be operation wise confirmation or milestone confirmations. Milestone confirmation means that if you confirm a certain operation in a task list, it would automatically confirm all the operations above it till it meets another milestone operation placed above in the sequence or in other words it will confirm all the operations from this milestone operation to an earlier milestone operation only. Whether you can print confirmations. Whether you can print this work center when you are printing shop floor papers for the production order.

Standard Text Standard text identifies a text that is frequently used to describe certain processes. Instead of including a Operation Description you can assign a Standard text and the description will be pulled in. Not so important field Operation Description Operation Description, describes the operation or sub-operation. This text is copied into the first line of the long text for the operation or sub-operation. Entering an operation description is not mandatory, but the Routing would look descent and informative.

Enter the Following in the Routing Operation Detail screen -

When you select the operation/s and press DETAIL OPERATIONS on the Routing Operation overview screen, then you would reach the operations screen. Where you can enter the following information: Base Quantity Enter a Base quantity for entering the standard values. Standard Values The Standard value key assigned to the work center will bring in the parameter assigned to it and you have to enter value for them. Entering the values for the standard value parameters is important to run the scheduling/capacity/costing formulas. For Example Work Center = FINISHING Base qty = 1 Piece Parameters Standard Values Set up Time 15 Machine Time 25 STEAM 2 ELECTRICITY 2

UOM MIN MIN KWH KWH

Activity Types ZSET ZMACH ZSTEAM ZELEC

Interoperation times Interoperation times are included in the operations to increase the total lead time. It behaves as offset times. Maximum Wait time It is the longest time that may pass before the material is processed in the next operation or order. In short it is an additional time between two operations. A wait time would increase the operation lead time. Minimum Wait time - It is the Shortest time that must pass before the material can be processed in the next operation or order. In short it is an additional time between two operations. A wait time would increase the operation lead time. Scheduling is always based on the minimum wait time. Standard Queue time = Time an order normally waits at the work center before it is processed. If the lead time of an operation must be reduced, the system can shorten the standard queue time as far as the minimum queue time. A queue time would increase the operation lead time. Minimum Queue time = Shortest queue time an order waits at the work center before it is processed. If the lead time of an operation must be reduced, the system can shorten the standard queue time as far as the minimum queue time. A queue time would increase the operation lead time. Standard Move time = Time normally needed between the current operation and the next one for the move from one work center (location group) to another. Move time does not increase the operation lead time but increases the total lead time of the order. Minimum Move time = Shortest time needed between the current operation and the next one for the move from one work center (location group) to another. Minimum move time from one operation to other is used if you are applying reduction strategies. Move time does not increase the operation lead time but increases the total lead time of the order. Note Normally consultants dont use the interoperation times, but if you insist you can do so. If it is a client requirement I would just use the move time which would not play around with the operation lead time but will just increase the total order processing lead time. & if you are confused on what is min and max and standard times just have the same values in both the fields. Reduction strategies - Also there is really no need to use reduction strategies in the operations (which would complicate lead time calculations).

Splits An operation is split if it is carried out on several machines or by several persons at the same time (see figure). This is only used in Routings and not in Recipes. Splitting an operation has the following effects on the operation dates:

The processing time/execution time becomes shorter. Setup and teardown must be carried out more than once for the operation.

If you want to use splits you should select the check-box indicator called Required Splitting. If you are using splits then the scheduling generation formula in the work center should be divided by the number of splits you enter here. Note When you are using Splits in a Routing, you can also mention a minimum processing time if you dont want the scheduling formula to reduce your total operation processing time (due to division by the number of splits) below a certain minimum processing time value. Note I havent seen many consultants use this. You can leave this field alone.

Overlapping Overlapping reduces the total lead time by starting the processing of the next operation before the current operation is finished. It does this by the use of minimum send ahead quantity after which the overlap should start and minimum overlap time. Continuous Flow overlaps When such overlap is triggered between 2 operations and both the operations are set for continuous flow overlap, the system calculates the lead times of both the operations individually after the overlap is complete and changes the lead time of the operation with the lowest lead time of the two to the lead time of the operation of the maximum lead time.

In other words if there are 2 operations, 0010 has lead time 1 hr and operation 0020 has lead time 2 hrs, operation 0010 will adopt the lead time of the operation number 0020. Note When you are implementing fresh at an organization, it becomes too complicated in introducing overlapping and splitting. You can do so slowly once you have implemented SAP and the users have become proficient enough (may be 2-3 years after go-live).

External Operation Processing When you are sending out an operation or sub operation for external processing to an external contractor, it also means that you are just send a partially finished header material to the subcontractor. Thus if you have provided all the purchase related information in the operation detail external processing section, the system will create a Purchase Requisition (PR) for the operation (the PR is not created for a material code but it is created for a text of the operation); this may seem odd as there would be no Material code on the PR. The following information is mandatory for external processing It is also mandatory for you to maintain a Control key for the operation or Sub operation that allows external processing. The components allocated to such subcontracting operation are assumed to be sent to the external vendor for processing. There can be a situation where some of the components which are allocated to the operation are not being sent to the vendor. In such as case you can predefine such components which are to be sent to the vendor with Material Provision indicator = L in the BOM Item Status Long text screen or You can do so in the Component Allocation screen by choosing Extra BOM and assign a value = L in the material provision indicator for those components to be moved to the vendor. (L to be provided to the vendor) Create and assign a Purchase info record for a subcontracting type for a particular vendor and with a correct purchasing organization. This Purchase info record should not be created for a material code but can be created for a material group or just directly enter the sort string, material group, planned delivery time for purchasing to identify the vendor while creation of the PR. You can also define a net price, price unit to make things easier for the purchase order creation.

Scrap Percentage in the Operation detail General Data Section A Predefined percentage scarp is assigned for the operation, if you know a fixed percentage by which production at the operation is reduced. The Scarp percentage reduces the production order quantities that is supposed to be produced at the operation; thus transferring a reduced amount to the next operation. Scheduling, capacity requirement generation and costing is affected proportionately for the operations involved.

User Specific fields

User defined fields are configurable. You can use user defined fields as process or production specific information or you can use them as parameters in scheduling, capacity or costing formulas since we have only 6 parameters possible in the work center standard value key. User defined fields can be used in operations and sub-operations. These configurable fields are placed under a field Key that acts as place holder for these user defined fields. The formats of these fields are given below: Up to four general fields for any text: You can use them to store information about people responsible, substitutes or telephone numbers, for example. Up to two quantity fields: You can assign additional formula parameters to the quantity fields in the field key. With the help of formula parameters you can use the values of the quantity fields in work center formulas, to calculate processing times, capacity requirements and costs. In addition there is also a field for the unit of each quantity field. Default values and their units which you have maintained in Customizing for formula parameters are transferred, but you can change this data. If you have entered data in the quantity fields and then change the field key, the old values remain unchanged. Up to two value fields: In addition there is also a field for the unit of each value field. Up to two date fields: Here you can enter internal start dates, for instance. Up to two checkboxes: You can use these to indicate whether an operation is to be included in evaluations in the Info System, for instance. Enter the Following for Component Allocation to Routing/Recipe The Routing operations are assigned with BOM components so that: a) Backflush Components which are marked as backflush are supposed to be issued automatically to the Production order at the time of Order confirmations. Thus all the components which are marked as backflush should be assigned to respective operations. b) Requirement date If components are allocated to an operation, the system can derive for you a requirement date of the component for the production order. This requirement date can help the materials management team and the shop floor operator to make the raw material available on the operation start date. Note - If component are not allocated to the operations, then the SAP automatically allocates all the BOM components to the first operation. This also means that all the backflush materials would be automatically issued when you confirm the first operation. And this also means that all the raw materials would be available for production on the start date of the first operation.

Method: To Allocate component to the operations, you have to press the "CompAlloc" Button or Use the path in the Operation Overview or Operation detail screen - Goto >>> CompAlloc Gen or CompAlloc Optn. Select the components and press "New Assignment" >>> A Pop-up Box will open up, which will ask you to enter the Opertion number to which you would want to assign the components to.

See the Screen shot below:

Enter the Following for Material Allocation to Routing/Recipe -

SAP Provides you with a facility to add header materials to the created Routing or Recipe (task list). In other words, you can just create one Routing/Recipe for one material and then go on

assigning header materials to the task list; this will indirectly mean that the task list which was applicable for the original material is now applicable for the header materials assigned as well. Assigning materials to a task list extends the task list to the other materials as well provided they also have exactly the same process of manufacturing, going through the same flow of operations. Method: You can press the Material Assignment Button in the Routing/Recipe Header Screen, which you open up a pop-up box that allows you to enter the material codes and the plant code (of the materials) to which you want to extend the task list to.

See the Screeshot below for further explaination:

Saving the Task list Saving the task list at the end would generate a Routing Group Number for the Routing Group. Even saving the recipe at the end would generate a Recipe Group Number.

Note: If you have not assigned an external Routing Group Number in the beginning (in the selection screen), then the system generates the Routing Group Number, which is an internally generated number.

See the ScreenShot below and notice the Group Number at the bottom of the Screen: