Control Recipe/PI sheet deletion procedure

By U.Nagarajan, HLL Lifecare Ltd Purpose: To explain the Procedural steps for deleting the Control Recipes/PI sheets which are created against the process orders. Sequential steps to be followed: Completing the PI sheet entries using CO60XT Sending &Deleing the PI Sheet using CO54

Steps in details: Step 1 Completing the PI sheet entries using CO60XT Go to CO60XT, Save& complete the PI sheet without entering any details and the make the status as completed

Step 2 Sending &Deleing the PI Sheet using CO54 Go to CO54 ,enter the plant, delete the creation date (from),enter the order ,select the To be sent &sent then enter

Select the line item and click the

button and then refresh

PI sheet sent status will be obtained as follows,

Now select the line item, go to Edit and then click Delete options

The PI sheet gets deleted from the list

Shift Note in SAP

By U.Nagarajan, HLL Lifecare Ltd 1. To create comments about a Person, Machine, an Event or other special points occurs within a shift or happened while executing the process orders that cannot be entered elsewhere in the system. (i.e., in a confirmation or maintenance notification, for instance). 2. Can be created with reference to a Process order, Work center, a hierarchy, or a resource PURPOSE (a) To document all important information and events that is occurring within a shift or while executing the Process order (b) Sending the informations to other recipients SEQUENTIAL STEPS INVOLVED Notification type for the Shift note-Creation Assigning Shift Notification type to the required resources Shift Note creation Sending Shift note to other recipients

STEPS IN DETAILS STEP 1 Notification type for the Shift note-Creation IMG Menu path Step 2 Assigning Shift Notification type to the required resources Logistics General Make Settings for Shift Notes Make Settings for Shift Note Type

SAP Menu Path T. Code

LogisticsProduction Process Master Data Resources ResourceCreate/Change

CRC1/CRC2

STEP 3 Shift Note Creation using SHN1 & sending to different recipients Go To SHN1 ,enter the Resource / Work center

After entering the Resource, press enter or click appears

button, the following screen

Enter the required details in the Comment Area

Click

button , the following message appears

Click

and then save ,the following screen appears:

Click the Recipient column, the following screen appears

Segregation of Valuable Components (ROHs/VERPs/SFGs) for reuse after Process order confirmation & after GR
By U.Nagarajan, HLL Lifecare Ltd Purpose: Segregation of valuable components (ROHs/VERPs/SFGs) for reuse (with the same batch number) after Process order Confirmation & after GR against the process order Procedural steps to be followed: (1) Entry of the rejection quantity in the Scrap column and the GI and GR to be done as per the procedure during the confirmation in transaction COR6N (2) GR for the scrap materials to be done in transaction MB1C. Steps in details: Step 1:Let us consider the following BOM in which the valuable component (I101011007) is in level 3, so that it will recover after the Level 1 GR:

Entry of the rejection quantity in the Scrap column after GI and GR done for the process order

261 details:

101 details:

Entry of the rejected quantities mentioned as 10 NO(mentioned in Orange color box ) ,the GI done for 100 NOs(Mentioned in green color Box)&GR 90 Nos done for the order Step 2: GR for the rejected material For recovering the component I101011007 10 Nos , the following steps to be carried out After confirmation, the stock of the component is shown as below:

Process Instruction (PI) Sheet

By U.Nagarajan, HLL Lifecare Ltd Process Instruction (PI) Sheet: Sheets to exchange data between the partially or completely manually operated production level

Features of PI sheet PI sheet can display Control information such as instructions for the Process operator in the Shop-floor on how to carryout the production step in effective manner Critical Machine parameters like Operating temperature, Die & Mould settings which are not captured in any form in SAP can be recorded with the help of PI Sheet

Sequential steps: Creation of PI sheet/Control recipe destination Creation of Process Message category Creation of Process Instruction Category Assigning Process message & Process Instruction Category to the Phase of the Master recipe C202 Generating Control Recipe-COR2 Sent Control Recipe-CO53XT PI sheet details entry-CO60XT

Steps in details: Step 1 Creation of PI sheet/Control recipe destination

Step 2 Creation of Process Message Category

Step 3 Creation of Process Instruction Category

Step 4 Assigning Process message & Process Instruction Category to the Phase of the Master recipe

Go to C202-Change Master recipe Enter the Material code/Recipe group to which the assignment needed

Select the phase and click

Enter the Process Instructions, Process Instructions category as follows and click any one Process instructions category

Enter the required Characteristic and the characteristic value as follows,

Save the recipe group Step 5 Generating control recipe-COR2: Go to T. code COR2-Change Process Order Enter the Process order number

Menu path for Generating Control Recipe:

Save the process order

Process Order Confirmation with Auto Goods Movement (Both GI & GR)
By U.Nagarajan, HLL Lifecare Ltd Purpose: To perform the Auto GI by using Back flush technique and Auto GR by using Control key during the Process order confirmation in COR6N Steps involved: Backflush indicator is to be made active for all the GI materials(ROHs/VERPs/SFGs) Creation of Control keys Assigning the Control keys to the Phase in Master recipe for which the Auto GR is required Material assignment to the corresponding phases in Master recipe Auto GI & GR during Process order Confirmation through the T.Code COR6N

Definitions: Back flushing -A technique through which automatic accounting of GI materials with 261 movement can be performed, at the time of process order confirmation Control Key- specifies the business functions to carry out with an operation. In the control key one can specify whether an operation has to be scheduled, whether capacity calculations should happen, whether the operation needs to be costed and whether auto goods receipt with 101 movements has to be carried out.

Steps in details:

I.

Activation of Back flush indicator for the GI material:-

Menu Path

Logistics -> Materials Management -> Material Create(general) -> MM01 > Procurement OR

Material Master Immediately -> MRP

-> 2 -

Logistics -> Materials Management -> Material Master -> Material > Change -> MM02 Immediately -> MRP 2 -> Procurement T. Code MM01/MM02

II.

Creation of Control Keys :-

IMG Menu T. Code

Production Planning for Process Industries -> Master Data -> data -> Define Control Key OP00

Master recipe

III.

Assigning Control Key to the phase :-

IV.

Material assignment to the phases :-

V.

Auto GI & GR :-

o In COR6N , enter the Process order number, select the Phase & Confirmation type and click on Goods Movements button

101-Goods Receipt for the order 261-Goods Issue to the order Save the Confirmation

Note: If the material is not activated by Backflush indicator and not assigned by the control key, then the GI & GR to be done separately through MB1A-261 movement& MB31-101 movement respectively.

Automatic batch determination for raw materials/packaging materials/semi finished goods during Process Order Confirmation
By U.Nagarajan, HLL Lifecare Ltd Purpose: To determine the Batches automatically based on FIFO while doing the 261 movement through Auto goods movement in COR6N by using Batch Search Strategy Technique. Sequential steps: Batch search Strategy creation through COB1 transaction Pre-requisites: Strategy type: a. Order Type/Plant/Material b. Order Type/Plant Search strategies ( will be created by MM) Selection criteria ( will be created by MM) Sorting rules ( will be created by MM) Creating the Classification view for SFGs in MM02 transaction Assigning the batches automatically during Process order creation (COR1) or in COR6N through auto goods movement Steps in detail I. Batch search Strategy creation through COB1 transaction Strategy Type & Strategies SAP Menu Path:

SAP MENU T.Code

Logistics Production Shop Floor Control Goods Movements Batch Search Strategy Create

COB1

Go to the Transaction COB1 ,enter the Strategy type:

After entering the strategy type, enter the Order Type , Plant &Material codes:

Note: Before the Creation of the Batch strategy, the Selection &Sort sequences columns are in deactivate condition (mentioned in Green colour box) Selection Criteria

After entering the material codes, select all the materials by clicking criteria button ,

and then click the selection

Click Class &Select the Required options

And click on button, then the following screen will display with the default selection with the tick mark for the particular material.

Similarly the selection criteria procedure has to be repeated for all the remaining materials

Sorting Rules

Now select the material by clicking

and then click the Sort button

Select the sort rule

Click Sort rule & select the required options

MRP Run in background for all Network Plants

By Divakar Rane, Suzlon Energy Limited Purpose: To understand how to take MRP Run in Background for All Network Plants, using Transaction Code:MDBT. Scope: To view Background MRP List. Method: Please follow the procedure as given below:

Transaction code Menu Path

MDBT SAP menu Logistics Production MRP Planning Total Planning MDBT--Background MRP

After filling information please click on Attributes. Here you need to do configuration for Scope of Planning (TCode: OM0E) or you can select single plant also. In Scope of planning you take multiple plants.

Here you select different option as per your requirement like protect variant. After Saving Variant you will get Variant SCM VB Saved.

Typical Production cycle in Process Industry

By R.Balaji, Infosys Technologies The below production cycle explains the basic business flow in Process Industry. The flow is generally focusing only on Production and Quality Management Simple Production Cycle: Consider all Raw materials are available in plant and production process yet to start, the following stages are to be followed 1. Create Process Order Here we are creating a process order based on the capacity of the equipments and resource availability 2. Release the Process order Once Process order created, it has to be released for production, means system will check the scheduling, material availability, capacity planning, etc., and then release process takes place 3. Goods issue from the Stores Once PO got released, goods issue against the process order will takes place 4. Start processing Product process against the PO will start 5. Confirmation Process After production, the final out put confirmation from the process will be entered 6. Goods Receipt Process Goods receipt process plays a major role in any business here we have to do 101 movement type and do the postings. In goods issue process they will issue the goods against PO in 261 movement type. 7. Quality Approval and Release Once GR from the production was made, the material will come to Quality control for approval. Here QC person will check the material and they will do the result recording and usage decision 8. Stock will appear in Unrestricted use for SALE / Further Process Once usage decision was made the material will automatically moved into unrestricted use. The FG is ready for sale By keeping above all points in mind, the following masters and transactions are required to proceed

S. No 1

Master

Transaction

T-code

Description

Where has to be used

MM01

Create Material

Used for creating Recipe and further tracking Machine / set of Machines used for making the product Here we are calling resource and materials required to make the finished product List of specifications to be checked for that concerned finished goods Creating Quality Plan Initiating Production creating Process Order Process by

CRC1

Create Resource

C201

Create Recipe

QS21

Create MIC

5 6

QP01 COR1

Create Quality Plan Create Order Process

MIGO with 261 movement CORK

Goods Issue Process

Goods issue to Manufacturing unit

Confirmation Process Quality Approval and Usage Decision

Production Process

Output

confirmation

QA32

QC will approve and release for further process

Step by Step Execution Process: Scenario Explanation: REQUIREMENTS: For a leading Process Manufacturing Company ABC, they are selling the product FG 1, the raw materials and resource requirements are listed below Raw Materials required for making 50kg of Finished Product, FG 1 are S.No Material Code / Material Type RM l 1 / ROH RM 2 /ROH BP 1 / FERT Material Description Quantity required Unit of Measurement

1 2 3

Raw Material 1 Raw Material 2 Byproduct

80 20 60

Kg Kg L

Resources required for making 50kg of Finished Product FG1 S.No 1 2 Resource Code CRC-001 CRC-002 Resource Description Reactor Vessel Capacity 2KL 4KL

List of MASTERS required for addressing the above scenario 1. Create Materials using MM01 transactions in the following way:

In this screen select select views button and extend the following fields

We have selected basic information entries field. Fill the information and finally select the General plant / storage data and give plant as 1100 and storage as 0001 in case of Raw material. The same procedure has to be repeated for finished goods and Co-Products, in plant storage data we have to give Plant 1100 and storage 0004. 2. Create Resource master using CRC 1 Transactio

Repetitive Manufacturing Cycle

By Umesh R Shinde, KPIT Info-systems

1. Create REM Profile using SPRO

SPROProductionRep ManufacturingControl Data Create REM Profile Using Wizard.

Production Order Splitting

Production Order could be split due to following reasons: 1. When partial lot of order is to be handled from the rest due to quality reasons. 2. If capacity bottle necks exists. 3. Material is committed for part of order qty. Features: 1. The split operations and the material assigned are copied into the child order. 2. The structure of the parent order does not changes while the split off operations are copied into the child order Status for Status for For operation : SPLT Restrictions: 1. The parent order and the child order must be settled to same cost collector 2. Read PP Master data is not possible 3. Confirmations at header level is not possible Steps to perform split: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. In OPL8 Set the indicator cost collector Default Rule -Periodic settlement(PP2) CK11N do standard cost estimate KKF6N Create cost collector Create production order with op10,20,30,40 Go to op overview Select the op from which you want to split (exop20) Go to functions ----> Split order Enter the qty ,if necessary a different order type for the child order Execute Order will be splitted . The order can be splitted even from op10 itself Goto MD04 Two orders will be created Go to op overview of each order and there you can see the splitting. parent the order child : order: SPLT SPLE

Routing Vs Task list Vs Work Procedure

By Mahesh Task list means the task which has to carry out on the shop floor and these are six types as you have mention. Routing is one of task list and this consists the series of operations requires for the production of an assembly at shop floor. Regarding the work procedure, you can define this in the work center default tab for the details about the work center and how to operate. this will be copied in operations while creating routings.

Convert Planned Orders to Purchase requisitions and Purchase Orders

By Mahesh We can create planned orders & convert them into purchase requisition or into production order. In the material master ,MRP2 view give the procurement type as 'X', for both internal & external procurement. Also include purchasing view for this material.

When you run MRP using md02, a planned order will be created for the requirement (Eg: say 100 no's given using transaction code MD61). Use transaction code MD04 to view the stock/requirement list.

Here double click the planned order, you can see tabs such as convert into purchase requisition, into production order, into process order. Click convert into Purchase Requisition & enter 50 Nos. Then a Purchase Requisition will be created which can be further converted into Purchase Order. Again come to md04 screen.

You can see a planned order & Purchase Requisition for 50 no's. This planned order can be converted into production order & 50 no's can be produced internally.

Difference between Co-Product and Bi-Product with an example

By Prasobh If you look at a petro chemical refining industry their main input material will be "Crude oil" during refining they get "Petrol", "Diesel", "Kerosene", "Naptha" & "Water" etc... So the whole of the production cost should not go to "Petrol" alone, as Diesel, Kerosene and "Naptha" are also sellable. Water is not sold out, but is being used internal for the operation. In this scenario "Petrol". "Diesel", "Kerosene" and "Naptha" are defined as co-products in the material master. And the cost which needs to be distributed among them are in the ratio 30:30:20:20, so in the joint production details we select the apportionment structure, and here we define the equivalence number by entering the materials and numbers as required by us as 30:30:20:20. Now BOM is defined for the main product "Petrol" and Diesel", "Kerosene", "Naptha" and Water are defined in -ve quantity. Here the definition of water goes as "BiProduct". Crude oil is defined as component in +ve quantity. Now during order costing/product costing/settlement considers the entire cost of production based on the crude oil cost and infrastructure cost and it splits into the ratio defined in the equivalence number.

Types of Subcontracting
By Chandra There are two types of subcontracting relevant for PP module: 1. Operation subcontracting 2. Assembly subcontracting. Operation subcontracting: Within in-house production if some capacity bottlenecks exists in any operations then you can this job to some vendors to carryout this job at his premises and supply us the semi-finished part. This can be done via control key example PP02 (external processing). Assembly subcontracting: Total product can be given for subcontracting. We have to give the raw materials to vendors and they would supply the assembly. This can be done with special procurement type 30 with procurement type F.

Process Order Confirmation with Auto Goods Movement (Both GI & GR)
By U.Nagarajan, HLL Lifecare Ltd Purpose: To perform the Auto GI by using Back flush technique and Auto GR by using Control key during the Process order confirmation in COR6N Steps involved: Backflush indicator is to be made active for all the GI materials(ROHs/VERPs/SFGs) Creation of Control keys Assigning the Control keys to the Phase in Master recipe for which the Auto GR is required Material assignment to the corresponding phases in Master recipe Auto GI & GR during Process order Confirmation through the T.Code COR6N

Definitions: Back flushing -A technique through which automatic accounting of GI materials with 261 movement can be performed, at the time of process order confirmation Control Key- specifies the business functions to carry out with an operation. In the control key one can specify whether an operation has to be scheduled, whether capacity calculations should happen, whether the operation needs to be costed and whether auto goods receipt with 101 movements has to be carried out.

Steps in details:

I.

Activation of Back flush indicator for the GI material:-

Menu Path

Logistics -> Materials Management -> Material Create(general) -> MM01 > Procurement OR

Material Master Immediately -> MRP

-> 2 -

Logistics -> Materials Management -> Material Master -> Material > Change -> MM02 Immediately -> MRP 2 -> Procurement T. Code MM01/MM02

II.

Creation of Control Keys :-

IMG Menu T. Code

Production Planning for Process Industries -> Master Data -> data -> Define Control Key OP00

Master recipe

III.

Assigning Control Key to the phase :-

IV.

Material assignment to the phases :-

V.

Auto GI & GR :-

o In COR6N , enter the Process order number, select the Phase & Confirmation type and click on Goods Movements button

101-Goods Receipt for the order 261-Goods Issue to the order Save the Confirmation

Note: If the material is not activated by Backflush indicator and not assigned by the control key, then the GI & GR to be done separately through MB1A-261 movement& MB31-101 movement respectively.