Anda di halaman 1dari 12

SAP PP Course Details

Overview
SAP Architecture
Master Data

Material master and material types


Bill of material

Work center resources

Routing, rate routing, recipes

Sales and Operation Planning

Standard planning
Planning with product groups

Planning with material

Product group aggregation and desegregation

Creation of plan

Planning methods level by level

Consistent delta planning

Transfer of plan to demand

Management and splitting

Master Planning

Demand planning
Planning strategies

Functions of demand management

Version management

Creation of planned independent

Requirements

Forecasting

Planning Material Requirement

Master data MRP

of

SAP

Planning with technique and business

Information

MR, procedures MRP, MPS & CBP(consumption based planning)

Carrying out planning run (MRP run) &Planning file

Control indicators processing key in MRP (NETCH, NETPL, NEPL)

Evaluation of planning results and planning table

Master production scheduling (MPS Run)

Processing planned orders

Availability check w.r. PIR & ATP Logic

Capacity planning & capacity leveling

Shop Floor Control (production Orders Discrete Management)

Production order maintenance


Copying master data

Scheduling basic date and lead-time

Scheduling

Availability check in production orders


Good movement and movement types

Production order confirmation

Others

Batch management
Material class

Batch status management

Batch determination

Class and classification

Material class
Batch class

Creation of objects

Creation of class and assigning of

Characteristics values

Integration with other modules: theory and integration settings

Module production costing in CO Module


Quality management QM Module

Materials management MM Module

Repetitive Manufacturing

Master data
REM Profile

Production versions

Rub schedule headers

Cost collectors

Preliminary cost estimate

Planning with planning table

REM Backs flushing

==================================================
===================================

SAP PP Sub Modules:


SAP PP - Discrete Manufacturing - Discrete manufacturing forms an industry type where in the
products which are manufactured can be easily assembled and dis-assembled. They can be
reworked upon easily to a large extent. You can say making pumps, engines, cars, airplanes.
SAP PPPI - Process Manufacturing - I feel that Process manufacturing forms an industry type
where in the products which are manufactured cannot be easily dis-assembled once they are
manufactured. It is impossible to be reworked upon these products. You can say making
chemicals, medicine, Towels, Paper, Steel etc.
SAP REM - Repetitive Manufacturing - I feel that Repetitive manufacturing form an industry
type where in the products manufactured can be discrete manufactured or process industry type,
produced repetitively or continuously in production lines. This forms the continuous production
scenario.

Master Data used in SAP PP/SAP PPPI

BOM A BOM is a list of components which are required for production of an assembly or
subassembly.
In SAP PP/REM BOM
In SAP PPPI BOM
Work Center / Resource
A Resource or a Work Center is a place where work is carried out. It is exactly the same
except for the category of the work centers in SAP PPPI is different.
In SAP PP/REM Work Center
In SAP PPPI Resources
Routing / Recipes
Routing or a Recipe has operations with work centers placed in a sequence of
production.
Routing in SAP PP/REM is very different than Recipe in SAP PPPI.
In SAP PP/REM Routing
In SAP PPPI Recipe
Recipes have Phases in place of operation which holds the work centers in a sequence
of production. Nevertheless operations are there which have significance other than
acting as header to the Phases. All the scheduling happens at the phase level.
Recipes also hold the Process instructions which are treated as information for the shop
floor operators or the legacy shop floor system on what is to be produced and how it is
to be produced and what qty is to be confirmed for production and how much is to be
received against the production order.
Such process instructions in turn except a return message from the shop floor about
order confirmations quantities at the phases, order Goods receipt quantities and other
QM inspection results and usage decision related data; these messages come back to
SAP as Process Messages and book confirmation, GR, QM activities in SAP Tables.

The Recipes also have one unique difference that they hold the BOM in them through
the use of Production Versions which carry these Recipes and BOM together. Thus
when you create a Recipe you need to create or enter a valid Production version for the
Header Material.
Such Combination of Recipe and BOM together might have also been set up together
because SAP PPPI has an inbuilt concept called Material Quantity Calculations, through
which you can change the quantity of component required through changes in
characteristics values of the header product & other production parameters.
Production Versions Production Versions in SAP PP/REM and SAP PPPI is the same.
A Production version holds the BOM and Routing/Recipe used for production for a lot
size and/or for a Validity period.
In SAP PP/REM Production Versions
In SAP PPPI Production Versions
Made to Order Vs Made to Stock Production
Process in a
Sequence

Made to Order

Made to Stock

Definition

When you specially produce and


When you produce according to a
deliver a product for a customer's
periodic forecasted demand and sell
order, it is called "Made to order"
the product to any incoming customer
Production. For example Production of who wants to buy them, it is called
Designer Jewelry, Production of
"Made to Stock" Production. Example
Areoplanes, production of Special type Mass Steel Production,
of steel, High end instruments and
vechiles etc.,

Demand Form

Customer Places a Sales order. A Sales When you produce against a Periodic
order for the demand is created in
forecasted demand it is called Made to
SAP.
stock production.
Sales order in some cases is referenced You can enter this forecasted demand
from a previous enquiry or quotation in a tool in SAP called Planned
of sales created.
independent requirements in the
system.
Planned independent requrirements can
also be derived/copied from Sales &
Operation Planning system which
contains demand from previous
periodic Sales figures from the sales
areas or Sales organizations or sales
area or sales offices or plants or
various combination of this (as per
your requriements). These previous
period figure for a product or a product
group can be extrapolated to create the
demand for the future periods.

SAP Production Every Material that is ordered should


Strategy
have a strategy that is - Made to order
Strategy = 20, set in the Material
Master MRP 3 View, Strategy Group
Field.

Every Material that is Produced with a


forecasted demand should have a
strategy that is - Made to stock
Strategy = 10, set in the Material
Master MRP 3 View, Strategy Group
Field.

Strategy 20 is used for Made to order


scenario, in which case the production Strategy 10 is used for Made to stock
is tagged with the customer order.
scenario, in which case the production
is not tagged with the customer order.
You should also set the Individual and
collective Indicator in MRP 4 to = "1" You should also set the Individual and
- Individual requriement which
collective Indicator in MRP 4 to = "2" specifies that this is an individual
Collective requriement or an field
requirement not to be clubbed and
value which "Blank" - Individual and
produced individually for a given
collective.
customer order.
Transfer of
Demand is Pushed to SAP MRP Tool Periodic demand is pushed to SAP
Demand to MRP
MRP Tool

MRP Net
MRP For its planning calculates the
Requirement
Net requirement planning
Planning for the
header Materials MRP analyses and evaluates the
Customer Demand for the Ordered
Material and while doing this it does
not check for availability of the
Materials in stock and considers it as
not available at the time of creating
procurement proposals in MRP.

MRP Evaluates the Planned Periodic


Demand for the Material and
while doing this it checks for
availability of the Materials in stock
and computes the shortage quantities.
MRP creates a Planned order for the
shortage quantities of this periodic
demand.

To get the Shortage Quantities - The


MRP Creates a Planned order for the system thereby compares available
total quantity of the customer order.
warehouse stock or the scheduled
receipts from Purchasing and
Production with planned independent
requirements, material reservations and
incoming sales orders. In the case of a
material shortage, that is, if the
available stock (including firmed
receipts) is smaller than the quantity
required, the system creates
procurement proposals.
MRP Net
After creating planned orders for the After creating planned orders for the
Requirement
header material, if a certain dependent header material, if a certain dependent
Planning for the requirement or component has a
requirement or component has a
Dependent
procurement type - "In-House", then: procurement type - "In-House", then:
Requirements
MRP then explodes the Bill of
MRP then explodes the Bill of
materials for the header Material and materials for the header Material and
plans the dependent requirements by plans the dependent requirements by
evaluating the shortage quantities
evaluating the shortage quantities
(Requirement qty - Available qty) and (Requirement qty - Available qty) and
dates of the components required in
dates of the components required in
production as per the BOM.
production as per the BOM.
While creating the Procurement
Proposals for the components, it takes
in to considerations the Lot sizing
procedures, special procurements,
Quota arrangements.

While creating the Procurement


Proposals for the components, it takes
in to considerations the Lot sizing
procedures, special procurements,
Quota arrangements.

MRP Planned
order for
Externally
procured
demands

After creating planned orders for the


header material, if a certain dependent
requirement or component has a
procurement type - "Externally
Procured", then:

After creating planned orders for the


header material, if a certain dependent
requirement or component has a
procurement type - "Externally
Procured", then:

MRP Creates Planned orders or


MRP Creates Planned orders or
purchase requisitions for the externally purchase requisitions for the externally
procured dependent requirement, only procured dependent requirement, only
for the shortage quantities
for the shortage quantities
(Requirement qty - Available qty).
(Requirement qty - Available qty).
While creating the Procurement
Proposals for the components, it takes
in to considerations the Lot sizing
procedures, special procurements,
Quota arrangements.

While creating the Procurement


Proposals for the components, it takes
in to considerations the Lot sizing
procedures, special procurements,
Quota arrangements.

The procurement proposal is also


scheduled which means that, for
materials procured externally, the
delivery and release dates are
determined, and for materials
produced in-house, the production
dates are calculated.

The procurement proposal is also


scheduled which means that, for
materials procured externally, the
delivery and release dates are
determined, and for materials produced
in-house, the production dates are
calculated.

MRP Explosion After Calculating the Proposal


After Calculating the Proposal
of Routing or
quantities for Inhouse Procuded
quantities for Inhouse Procuded
Receipes
Materials, the System explodes the
Materials, the System explodes the
Routing or Recipes (if MRP is set at Routing or Recipes (if MRP is set at
Lead time scheduling) which helps in Lead time scheduling) which helps in
correctly evaluating the basic order
correctly evaluating the basic order
start date and basic order end date.
start date and basic order end date.
MRP system calculates the operation MRP system calculates the operation
execution dates and inturn the order
execution dates and inturn the order
execution time from a forward start
execution time from a forward start
date or from a backward end date
date or from a backward end date
provided (normally set at backward
provided (normally set at backward
scheduling in Scheculing Parameters scheduling in Scheculing Parameters
customizing). Material floats and
customizing). Material floats and
operation floats (buffers) are taken into operation floats (buffers) are taken into
account while deriving the dates.
account while deriving the dates.
If MRP is set at Basic Scheduling If MRP is set at Basic Scheduling Then the basic start date and end date Then the basic start date and end date
is calculated using the flat Material
is calculated using the flat Material

Conversion of
Planned orders

Master Lead times.

Master Lead times.

Once the Planned orders and Purchase


requisitions are created, they are
converted to Production orders or
Process order/Purchase orders.

Once the Planned orders and Purchase


requisitions are created, they are
converted to Production orders or
Process order/Purchase orders.

Production Supervisors or
Production Supervisors or
Planners convert the planned orders to Planners convert the planned orders to
Production orders or Process orders. Production orders or Process orders.
Purchasers would convert the Planned Purchasers would convert the Planned
orders or Purchase requisitions to
orders or Purchase requisitions to
Purchase orders.
Purchase orders.

Production order Production order adopts the planned


creation
order information such as Quantities,
Basic Start Date, Basic Finish Dates,
operation dates, component quantities.
Production Orders are created and
released on the shop floor. Before
saving and releasing the order, the
production scheduler or planner can
change the quantities, dates and
component quantities, operation
scheduling information.

Production order adopts the planned


order information such as Quantities,
Basic Start Date, Basic Finish Dates,
operation dates, component quantities.
Production Orders are created and
released on the shop floor. Before
saving and releasing the order, the
production scheduler or planner can
change the quantities, dates and
component quantities, operation
scheduling information.

The Production order which is created The Production order has no link to
has a link to the customer order.
any customer atall.

Purchase order
creation

Purchase orders which are created


through the conversion process are
released and sent to the Vendors.

Purchase orders which are created


through the conversion process are
released and sent to the Vendors.

Production order Once the Production orders are


Once the Production orders are
Shop Floor
Released, they are thrown on the shop Released, they are thrown on the shop
Execution
floor for Production:
floor for Production:

Goods issue to
the Production
order

a) Every Operation confirms the


production against each order once
they produce the required quantities of
that order.

a) Every Operation confirms the


production against each order once
they produce the required quantities of
that order.

b) Once all the operations are


confirmed for all the quantities, the
production order gets the status "CNF"
- Completely confirmed.

b) Once all the operations are


confirmed for all the quantities, the
production order gets the status "CNF"
- Completely confirmed.

At the time of confirmation or Parellel


to the Confirmation process or after
the confirmation process, the
supervisor/respective operator issues
the components to the production
order.

At the time of confirmation or Parellel


to the Confirmation process or after the
confirmation process, the
supervisor/respective operator issues
the components to the production
order.

The Operator or Supervisor gets a list


of all the components that are required
for production through a reservation
list created in SAP (a reservation list is
created for every order at the time of
order creation).

The Operator or Supervisor gets a list


of all the components that are required
for production through a reservation
list created in SAP (a reservation list is
created for every order at the time of
order creation).

Goods Receipt The Products which are fully


from the
manufactured against the order are
Production order received to the "Finished Goods
Storage Location" through a SAP
Material Movement called "Goods
receipt against the Production order Movement type 101".
The Received Materials in a MTO
scenario have a tag of the customer
order and customer against them and

The Products which are fully


manufactured against the order are
received to the "Finished Goods
Storage Location" through a SAP
Material Movement called "Goods
receipt against the Production order Movement type 101".

they cannot be issued or delivered to


any other customer order.

Order
Settlement

Orders which are received in to stock Orders which are received in to stock
are settled by the finance team.
are settled by the finance team.

==================================================
====================
PP- Master Data
Set Up

BOM

Work Center

Routing

SAP Tables
MRP

MRP Views
Lot Sizing Procedures
Procurement Proposals
Evaluation of MRP Results
Tables in MRP

Discrete Manufacturing

Planned Orders

Production orders

Order Types

Scheduling

Goods Issue

Goods Receipts

Status Profile
Repetitive Manufacturing

Production Versions

Planning Table

Back flushing
Sales and Operational Planning

Sales Forecast
Production Plan
Demand Management

Planning strategies

Planning with final assembly

Planning without final assembly

Planning at assembly level

Net Requirements planning

Gross requirements planning

Make to order strategy


KANBAN

Supply Area

Kanban Board

Supply Source

Demand Source
Functional SPEC

How to create a functional spec with real time examples

Extracting data from Tables

Anda mungkin juga menyukai