PMPL Configuration Document

PRODUCTION PLANNING
Project:e-Jagruti

Configuration
Document

PRODUCTION PLANNING

Version Date Title /Module Prepared /Changed

Configuration Document PP Consultant

01 01.03.2008 PRODUCTION K.Sudhir Goud

PLANNING

SAP R/3 version : mySAP ERP ECC 6.0

Project Manager(Bigtec Pvt Ltd): Mr. Chinmoy K Patnaik

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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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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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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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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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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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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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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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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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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 is
used 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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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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PARAMETERS –MACHINE :

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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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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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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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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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In 1100, 1200&3200 for machine hours the following formula is used

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Scheduling formula

Costing and capacity requirements formula

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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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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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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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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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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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PATH> Production ~ Material Requirements planning ~ Master Data ~ Define MRP

Controllers

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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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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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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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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 and
Rough-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 the
dependent requirements to the operation dates were done

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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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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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PATH> Production ~ Material Requirements planning ~ Planned file Entries ~ Activate

MRP and set up Planning File

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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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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,SP01
with 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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PATH> Production ~ Shop floor Control ~ Master Data ~ Order ~ Define Order Type –
Dependent parameters

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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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PATH> Production ~ Shop floor Control ~ Master Data ~ Order ~ Define Number
Ranges for orders

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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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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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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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PATH> Production ~ Shop floor Control ~ Operations ~ Availability Check ~ Define

Checking Control

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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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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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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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In the second areas of the general individual entry the partial confirmation is allowed for the
confirmation type.

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In the second areas of the general individual entry the partial confirmation is allowed for the
confirmation type

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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 ~ Define

Settlement

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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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