Introduction to SAP PPPI - Process Manufacturing

My definition to "Process manufacturing" is that it is a form of an industry type where in the products which are manufactured cannot be easily assembled and dis-assembled. It is impossible to be reworked upon these products. You can say making chemicals, medicine, Towels, Paper, Steel etc.

With the above definition of a process industry in prespective, SAP offers SAP PPPI or SAP PI which can be used to implement business processes in a process industry. A Master Recipe is a task list in SAP PPPI or SAP Process manufacturing. SAP uses the master recipe when creating the process order. In discrete manufacturing, the task list used is called a routing. The purpose of both of these task lists stands the same, which is scheduling, capacity generations, generating planned costs and component scheduling. The major and the only difference in SAP production planning (SAP PP) and SAP process industry (SAP PPPI) is the master recipe and the process management embedded as the part of master recipe. The master recipe is conceptually identical with the routing/rate routings though there are some major differences which separates them. These differences are explained below: a) Production Versions and their use in Master Recipe Vis--vis the routing or rate routing, the master recipe collects the operations and the BOM together in one master data through the use of production version. The production version is exploded in the recipe to pull in the material BOM. Bringing the BOM inside the task list helps in generating one more unique feature of a recipe called the Material Quantity Calculations. The material quantity calculations helps to change the component quantities and the header material quantity vis--vis each other and with respect to the values of the active ingredients (batch classification specifications) of the components and the header material. Before creating the recipe, one should have a Production version created with at least the BOM embedded in it, which will help adding the BOM to the recipe. Very Important Note It seems to be a normal practice that the recipe group number is added to the production version after it is created. So you may have to maintain the production version
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information, firstly after the BOM creation and before the recipe creation and once after the recipe creation so as to assign the Recipe group number to it.

b) The concept of phases and operations in a task list A master recipe has the concept of operations assigned with phases vis--vis discrete manufacturing which has only operation level details. The introduction of phases helps the organization to break down the activities on an operation (as phases) and detail them out. The standard values/activities like the set-up time or duration or machine time etc; are assigned to the phases in process manufacturing unlike discrete manufacturing where they are assigned to the operation itself. This takes you to an obvious conclusion that the confirmation in process manufacturing are carried out at the phase level rather than at operation level. As discussed in the above paragraph the master recipe has an added capability to carry out material quantity calculations for the header material as well as the components, where in you can change the component quantities and the header material quantities based on the characteristics values of their respective batch classes and through formulas written as macros.

c) Process Management The master recipe also comes with a feature called as the process management, which is primary differentiator between the Routing and the Recipe. A master recipe attaches process instructions to the phases; these process instructions carry process notes, order details, phase details, component details, quality inspection details, goods receipt details. The process instructions are bundled up into a control recipe and are sent to the control recipe destination, which once sent to the shop floor operator or the process control system, helps them to with the detailed information and instructions about the order and initiates a trigger to start manufacturing activities. The process instructions also contains information on the Process messages which are supposed to be sent back to SAP (data requests), like the confirmation records for the order; goods issue records for the order and goods receipts data for the order, inspection results for the received goods etc. Eventually the processes messages post the data in SAP tables using various BAPIs and functional modules.

An individual process instruction for example a process instruction for order information, contains characteristics like the order number, plant code, order type, order start date, order finish date, order reservation number, header batch number (if any) etc. These characteristics carry the respective values. You can manually change/add the values or have them populated by the system (for example for characteristics like order number, order start date, order type etc ;) as per the process design. The characteristics used in process instructions to carry values of various parameters are always assigned with a characteristics group called as PPPI_INST. The process instructions can be assigned to the master recipe with product or process specific values assigned in them or they can be assigned to the control recipe destination itself. Assigning the process instructions at the control recipe destination would automatically explode them in the process order and this avoids the effort of individually assigning them at the material/plant level master recipes. For process instruction attached to the destination, you could still assign values to them but they would not be material specific and would be very generic in nature which is applicable to the processes carried out at the destination. The Process instructions are bundled up in a control recipe which is downloaded from SAP and sent the control system or the shop floor operator. The Recipient processes the process order and sends activity completion process messages to the SAP system in the form of process messages. Correlation One can correlate the process instructions as an examination Question Paper set for a particular grade with instructions and questions in it. This question paper (as process instructions) is given to each and every student belonging to a particular grade (a grade can be a control Recipe destination) along with the process message request to answer the questions in a particular set time (consider the filled up answer sheet along with the Roll number and grade as process messages which are requested back by the system). The students are expected to carry out the activities of answering and appearing for the test and in return submit the answer sheet as process message back to the examiner (the examiner can be the SAP system which updates the completion information and marks in SAP system) Standard SAP in SAP PPPI is designed to have the recipient as a shop floor operator in SAP itself, who completes the order detailing and manufacturing in PI SHEETS and sends back the process messages to the SAP cockpits to process standard designed BAPIs. On the other hand if the recipient is a process control system outside of SAP, he can also receive or request the instructions in a control recipe to aid in production and send back the messages to SAP system through standard interfaces designed for such integrations between SAP and the external shop floor control system.

Figure 1

Control recipe Destinations

Standard SAP has control recipe destinations which receive the process instructions and using which the destination carries out the manufacturing and at the end of which they send back the process messages to confirm their production activities or production status on a real time basis. The control recipe destinations are assigned to the individual phases of an operation; which means that every phase in a master recipe can carry different control recipe destinations. One control recipe is created for a given destination and order combination. The destinations or recipients of the process instructions can be SAP destinations or external process control system destinations. If the destination is in SAP itself, then it can be a shop floor operator/operator group at a plant or a production line or shop floor operator/operator group for a specific activity, executing the phase; where as if the destination is an external process control system outside of SAP, then the process instructions & process messages are interfaced with that external system. The definition of the control recipe destination needs configuring the destination type, address of the destination (in external system, the address is the RFC destination of the process control systems). Control Recipe Destination 1&4 SAP External Control System

Destination lies in SAP ERP system Destinations lies outside of SAP ERP system and is called as an External Control System

2&3

Control Recipe Destinations Type 1 & 4 - Destination located in SAP ECC System For shop floor destinations which are in SAP itself, there are 2 different types of destinations called 1 and 4, to represent them. The destination operator group of type 1 receives all the process instructions & requested process messages well arranged on an ABAP based sheet or screen called as a PI-Sheet (one for an order, for a destination). Whereas for a destination of type 4, a sheet containing all the process instructions and requesting process messages, well arranged on a web based sheet browser based PI-Sheet is sent to the internal operator/operator group.

Note: An ABAP based PISHEET is shown below, if the same is set for a destination type 4 browser based PI-Sheet, then the sheet with the information would appear in a browser in HTML format. With Destination type there are standard BAPIs and connections working, which would process the messages once sent back to SAP by the respective destinations. Note: In configuration for the destinations of type 2 and 3, you can assign process instructions which would be automatically become a part of control recipe and would be downloaded to the external control system. Whereas for destinations of type 1 and 4, there is a provision to assign the process instructions in a sequence (making a list of suitable instructions) which are generated in the process order control recipe and subsequently downloaded to the SAP operator/operator group. Note: Transaction to create the Control Recipe destination is O10C.

ABAP Based PISHEET

Order Information

Process order number Process order type Plant Process order Quantity Control Recipe number Reservation Number Destination Date/Time

10002569 PI01 0002 10 100000000029823 561543 01 Shop Plant 0002 25th Dec 2010

Operation/Phase Information Operation Phase Description Phase Relationships Start Date & Time Finish Date Destination & Time 01 01 01 01

0010 0010 0020 0020

0011 0012 0014 0015

Component Information

Operation 0010 0010 0020 0020

Phase 0011 0012 0014 0015

Component C1 C2 C3 C3

Description C1 C2 C3 C4

Qty 10 20 10 15

UOM

SLOC

Batch

Requesting Phase Confirmations Operation Phase Yield Scrap Set up Time Machine Time Text Reason

Requesting Goods Issues Component Qty C1 C2 C3 C4 UOM C1 C2 C3 C3 SLOC Batch Component Description Text Reason

Requesting Goods Receipts

Dynamic Function Call for MIGO_GR Transaction Code Press here to access MB31 T - code

Control Recipe Destinations Type 2 & 3 - Destination outside of SAP (External Systems) For control recipe destinations lying outside of the SAP system, i.e., external process control systems or manufacturing execution systems lying outside of SAP, the process instructions are sent their through a standard designed interface. There are majorly two control recipe destinations interacting with external process control systems, namely 2 and 3.

Destination type 2 is used when the SAP initiates the transfer or download of control recipe to the external process control system (Push case); whereas 3 is used when the transfer or download of control recipe is triggered by the external control system (Pull case). Note - When the process control system is an external system, you can assign the process instruction categories and have the system generate control recipes automatically. Note: In configuration for the destinations of type 2 and 3, you can assign process instructions which would be automatically become a part of control recipe and would be downloaded to the external control system. Whereas for destinations of type 1 and 4, there is a provision to assign the process instructions in a sequence (making a list of suitable instructions) which are generated in the process order control recipe and subsequently downloaded to the SAP operator/operator group. Note For external control systems, it is required to define a RFC destination, so as to define the connections to the control system and enable SAP to communicate with the system. The transaction code to create is SM59.

Figure 2

Figure 3

Master Recipes in SAP PPPI

Just as discussed in the Routing task list section, the master recipe creation is very similar to it. One could create task list groups and then assign the material to it or one could create a master recipe task list for a producible material directly. The transaction code to create a master recipe is C201 (Change is C202 and Display is C203); whereas the transaction code to create a process order is COR1 (Change is COR2 and Display is COR3). In this section, the master recipe and the process order is explained together. The logics or the configuration to select the BOM, Task list in the process order remains the same. The only evident difference is that every manufactured product needs to pull in the BOM and the master recipe based on production versions and therefore the MRP 4 view of the material master needs the BOM selection procedure as 2 - Selection by production version or 3 - Selection only by production version. Note a) It is needless to say that the configuration required just for the master recipe is similar to that of the Routing or rate routing settings and b) The configuration required for creation of the process order is similar to that of the production order configuration. c) One should also carry out the BOM selection configuration along the task list selection configurations just as explained in the production order section. d) Additional configurations required for SAP PPPI are only for the use of process management, if you decide to use process management functions such as process instructions, control recipe destinations, RFC destinations for control recipes, process messages etc.

Notable Key Differentiators between Master Recipe and Routings are explained in the following below text boxes:

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Key Difference between SAP PP and SAP PPPI

a) Use of Production Versions in a Master Recipe When one creates the master recipe for a material-plan combination, it is recommended to enter the production version for the material on the selection screen. The production version should be created prior to the creation of the master recipe and then used for creation of the recipe. A production version can be created in the material master MRP4 view or Work Scheduling view. A production version is used in creation of a master recipe so as to identify the BOM for the material and pull the bill of material details in the recipe. The master recipe requires a profile assignment for creation of a recipe, the profile (as any other profile) contains some default value for some fields like the default control key, default operation number increment, default user field key, default phase relationships, default network creation parameters, default process instructions increment number. One can create the process instructions using the transaction code OPN1 or OPN0.

Figure 4

First strategy to create the master recipe: a) Prior to the creation of the master recipe, one could create the production version with the BOM details included (and without the master recipe group number & counter number details)

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b) And then use this production version for the creation of the recipe. c) After the creation of the master recipe, you can go back and enter the master recipe details in the production version.

Second strategy in creation of the master recipe as below: a) Create a (blanket) master-recipe-group without any reference to a material/plant, b) Then create the production version with this master recipe details along with the BOM details, c) This would mean that the master recipe which was created earlier had no connections to any material list (BOM) and you could now solve this issue by assigning the header material to the recipe triggering the system to prompt you to enter the production version details so as to explode the BOM in the recipe.

b) Recipe Header details in creation of a Master Recipe The master recipe header is very much similar to the header of a routing/rate routings in SAP PP (discrete manufacturing). It contains the following:

a) The lot size quantities for which the master recipes are valid are given as charge quantity range. b) The master recipe header also contains the default values for the operation/phase/secondary resources. It states the default values for deciding the operation quantities and its unit of measure versus the recipe quantities and its unit of measure in proportionate relationships. In Routings or rate routings, such relationships are directly mentioned in the operation details. SAP provides a very nice example to demonstrate the same, i.e., when the recipe unit of measure is pieces and the operation unit of measure is kilogram and for every 5 kg of the operation there are 3 pieces of the recipe, then the quotient is 3/5. The charge quantity is 3 pieces and the operation quantity is 5 kg. SAP also provides a base quantity to play around with the situation in a more detailed fashion.

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Figure 5

b) Operation and Phases in creation of Master Recipe A master recipe has the concept of operations assigned with phases vis--vis discrete manufacturing which has only operation level details. The introduction of phases helps the organization to break down the activities on a given operation as phases and detail them out. The standard values/activities like the set-up time or duration or machine time etc; are assigned to the phases in process manufacturing unlike discrete manufacturing (where they are assigned to the operation itself). This takes you to an obvious conclusion that the confirmation in process manufacturing are carried out at the phase level rather than at operation level. Note the following amusing things in a master recipe which are unfortunately not a part of the routing or rate routing:

a) The Resource (work center) is assigned at the operation level. The phases adopt the resource which is assigned at the operation level. The phases behave as something similar to sub-operations).

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b) The work center assigned to the phases also carry a QDR system which is something but the address of an external control system to which data has to be sent, in cases when the control recipe destination is an external process control system. The QDR field can be configured in SAP.

c) The standard values/activities which are assigned in the resource are active at the phases level and not at the operation level. You can enter the values of standard values/activities at the phase level unlike in routings/rate routings. The summation of the standard values at the phases is the total time required to process the operation. The operation in process manufacturing (SAP PPPI) has no meaning unlike discrete manufacturing where everything is executed at the operation level. Even the components of the BOM in SAP PPPI, are assigned to the phases and not the operations, thus strengthening the fact that the phases govern over the operations. Though the inspection characteristics can be assigned at both operation and phase level in case of QM in process inspection. To create a phase below the operations, you have to select the phase indictor.

d) In SAP PPPI, the phases (of an operation) are sent outside for external processing. The external processing details are entered at the phase level.

e) The relationships between phases can be maintained as start-finish, finish-start, finish-finish or startstart, in other words the phases can work in parallel or in a overlapping situation. It should be well noted that connecting phases of 2 different master recipes would connect two process orders and scheduling them as one unit (depending upon the relationship that exists between the 2 phases belonging to the 2 master recipes of 2 different producible products.

f) You can access phase relationship screen for phases (operations tab) by selecting the phases and going to the path Goto > Relationshipsin master recipes create/change/display modes.

g) The Control recipe destination is assigned to the phases during the creation of the phases of an operation.

h) The process instructions are assigned in the master recipe to the respective phases. As discussed earlier some or all the process instructions can be assigned to the control recipe destination in IMG; though you can insert all the process instructions during master recipe creation itself increasing the total effort. For specific process instructions which have characteristic values based on material, then those instructions have to be assigned at the master recipe level.

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i) To assign Process instructions to the phases, you can use the path in operation tab of the Master recipe Goto > Process Management > Process instructions.

Figure 6

c) Embedding Bill of Materials in Master Recipes Vis--vis the routing or rate routing, the master recipe collects the operations and the BOM together in one master data through the use of production version. The production version is exploded in the recipe to pull in the material BOM. Brining the BOM inside the task list helps in generating one more unique feature of a recipe called the Material Quantity Calculations. Before creating the recipe, one should have a Production version created with at least the BOM embedded in it, which will help adding the BOM to the recipe. Very Important Note It seems to be a normal practice that the recipe group number is added to the production version after it is created. So you may have to maintain the production version information, firstly

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after the BOM creation and before the recipe creation and once after the recipe creation so as to assign the Recipe group number to it.

Figure 7

d) Material Quantity Calculations It is true that with the use of a BOM, the component quantities in a process order are calculated as directly proportional to the order quantity, and the product quantity cannot be altered with respect to the component quantities and their ever varying specifications. But this truth can be falsified in process manufacturing through the use of a concept called material quantity calculations, which allows changing the following in a process order, provided you have maintained the material quantity calculations through formulas in the master recipe: a) To change header product quantities, with respect to the component quantities or with respect to the active ingredient proportions. b) To change the component quantities with respect to each other or the header product or with respect to the active ingredient proportions (batch characteristics and their values). c) To calculate the planned phase scrap and include it in planned cost. d) To change operation/phase quantities when they are not proportional to the product quantity.

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A material Quantity calculation requires definition of production version in the master recipe. A production version allows the system to identify the BOM related to the recipe and the list of components that needs to play with. Planned scrap for the component, as entered in its material master, increases the component quantities automatically. You could also use the planned scrap of a component as a variable in calculating other components material quantity calculation formulas. The Process order accepts these equations and processes them automatically if the batch allocation is not a criterion (taking active ingredient concentrations from the batches). For formulas which are supposed to be processed at batch level and which uses active ingredient proportions (batch characteristics values) in them, the material quantity calculations have to be manually triggered in the process order after the batch determination. (It is evident that only numeric batch characteristics are entertained here). If no batch has been assigned in the process order, then the material lines quantities or batch characteristics values at the material line, as entered in the material master are taken in to account. (When we assign the batch characteristic values at the material master batch class level, it is considered as a default value which can be overwritten during goods receipt from process order). After the BOM is exploded in the master recipe, you can enter into material quantity calculations screen through the path Goto > Material Quantity Calculation Following is an example and steps explained to execute the same: a) Once you are in the material quantity calculations screen, keep your cursor on the field for which you want to change through the use of formula and press the Select formula button. b) In the formula box, you can enter the formula equation that derives the output field value. c) While creating the formula you can double click on the variables that you want to include in the formula or just keep the cursor on the variable and press the button Insert in formula The operators like +, -, *, /, DIV, MOD can be selected on the screen. The functions for use of exponential, absolute values (ABS), rounding (ROUND), truncation (TRUNC), square root (SQRT), IF THEN ELSE conditions, IF THEN NOT conditions, EXP, LOG, SIN, COS, TAN, are also available for use.

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Figure 8

Method to enter the formula: Step a) To enter formula for header material quantity Place double click on the field showing header material quantity M1P1:Quantity =[001,001]

Step b) Intended Formula for M1P1 Quantity = [004, 001]/0.8

Step c) Press the enter button to save the formula and press the execute button to transfer the calculated material quantity to the material list and BOM
Line Object 1 Qty [001,001] M1P1:Quantity 2 Characteristics- 3 SPEC1 Phase scrap 4 Interim results

M1P1

Operation 0010

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3 4 5 6 7 8 9 10

..Phase 1 Comp: M2PPI ..Phase 2 Comp: M3PI Operation 0020 ..Phase 1 Comp: M4PI Phase 2 [004, 001] [004, 002]

Other Formulas which you can create They are not shown in the screen shot: Calculating the quantities of component M2PI (field location [004, 001]) = Product Sum of all the assigned batch quantities (assigned to component M2PI) = Component Batch Qty * Characteristics value of SPEC1 for the batch = CPSM(004;002) = 20*0.7 + 50*0.8 = 54 Formula in general = CPSM(<material item>;<Characteristics Column>;<Characteristics Column)

Line Object

1 Qty [004, 001] 70 20 50

4 5 6

Comp: M2PPI Batch B1 Batch B2

2 CharacteristicsSPEC1 3 Phase scrap [004, 002] 70% 80%

4 Interim results

Similarly you could have a formula for quotient Sum of all the assigned batch quantities

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= CQSM(<material item>;<Characteristics Column>;<Characteristics Column) = (Qty1/Characteristics1) + (Qty2/Characteristics2) + (Qty2/Characteristics2)

Step d) After saving the formula, you can press the calculate quantity product button to test the formula. e) Assignment of Process Instructions to the Master Recipe To assign Process instructions to the phases, you should select the phase and use the following path in the operation tab of the Master Recipe Goto > Process Management > Process instructions. To check or change or add values to the characteristics, you can go to the characteristics details by using the path in the below screen Goto > PI Characteristics overview Explanation of the Screen shots below: If you have a look at the below screen shot, there are only 2 process instructions, one containing the order details (AORD_1) and (APROD_1). The process instructions APROD_1 is created with characteristics containing process message details or process message requests seeking goods receipts information from the shop floor. The details required for the goods receipt in SAP are requesting in the form of characteristic values. Both these instructions are pointed for download to the shop floor system with control recipe destination Z1 pointing to the shop floor system and having a destination type 2 Download to PCS (process control system) initiated by SAP. Alternatively you could have a destination type 3 which is downloading to PCS initiated by the external system. Process Instructions Assigned to Phase 20

Figure 42

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Process Instructions Characteristics for AORD Sending Order information to the Destination

Figure 43

Process Instruction Characteristics for APROD_1 Sending Process messages details in the process instructions to request Goods receipt information

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Figure 44 SAP PPPI Process Management

Overview of Process Instructions Categories and Process Messages Categories Process instructions categories are assigned to the phases in a master recipe. Upon creation of the process order, the system calls the relevant master recipe, thus pulling in the operation list, material list and the process instructions. The process instruction categories are used in SAP PPPI Process Management to send process order/process specifications information to the control recipe destination and to receive the requested information from the control recipe destination to process data records in SAP.

In short Process instruction categories are used as a device to send information to the Destination, this information can be a) Process notes, process specifications; process order related information. b) It can be the information of data requests which are to be sent back to SAP for processing the manufacturing data records in SAP.

Purpose of Process Instructions: a) A Process Instruction list contains process instructions which send information and notes to the destination, such as order details or phase details or material consumption details or process parameter notes.
Process Instruction Category - ZPPI_XYZ1 Sending Process Information Process Instruction Characteristics PPPI_INSTRUCTIONS PPPI_NOTES Automatic Value Input Value X X Value

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b) Reporting back the consumption data, confirmations, goods receipt, and quality inspection results, to SAP is an activity triggered after completion or partial completion. To enable the system achieve this, SAP sends process instructions categories which contains the respective process message category and process message characteristics which are to be filled in by the process control system and sent back to SAP. For example, if you are expecting back the goods receipt information, the system expects the values for material produced, quantity produced, the unit of measure of the same, the operation/phase information, the process order against which it is to be posted, the plant, the event time/date information and whether it is a final postings etc. A Process message category with all the information filled in it is posted to SAP through defined BAPIs or Function modules in the process message category. In our example below the process message category PI_PROD contains all the process message characteristics whose values are filled in by the process control system and posted back to SAP and processed in SAP for goods receipt against a process order.

Very important Note - If you see the table below, in a process instruction category carrying the process message category (which is requesting data back to SAP), the value column would contain the process message categories or process message characteristics.
Process Instruction Category - ZPPI_XYZ1 Process Instruction Characteristics PPPI_MESSAGE_CATEGORY PPPI_PROCESS_ORDER PPPI_REQUESTED_VALUE PPPI_REQUESTED_VALUE PPPI_REQUESTED_VALUE PPPI_REQUESTED_VALUE PPPI_REQUESTED_VALUE PPPI_REQUESTED_VALUE PPPI_REQUESTED_VALUE PPPI_REQUESTED_VALUE Automatic Value X X X X X X X X X PPPI_OPERATION PPPI_PHASE PPPI_MATERIAL PPPI_EVENT_DATE PPPI_EVENT_TIME PPPI_EVENT_TIME PPPI_MATERIAL_PRODUCED PPPI_UNIT_OF_MEASURE Input Value X Value PI_PROD

Briefing on Control Recipe Destination If the control recipe destinations are of type 1 or 4, then PI Sheets are sent to the destination (SAP operator groups). A control recipe is created at the time of release of the process order, which bundles up all the process instructions for a given destination and for an order in the form of a PI Sheet. The PI sheets contains process instructions categories in a form-layout containing process notes or process order related data along

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with the data requests for confirmations, activity confirmations, goods issues, goods receipts, inspection results, that are to be sent back to the SAP tables in the form of process messages. In such cases too, the system receives the data from the destination in the form of process messages and then uploads them in to SAP tables using functional modules and BAPIs. If the control recipe destinations are of type 2 or 3, then Process instruction categories are bundled up in a control recipe, for a given destination and for a given process order and are sent to the external system. The purpose of the process instruction categories carrying process notes or process data requests remains the same.

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