http://scn.sap.

com/docs/DOC-54372
Standard Value calculation Via CAPP- an
Overview
created by Mohan raj Natarajan on 18-Apr-2014 11:07, last modified by Mohan raj Natarajan on 21-Apr-2014 08:51
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CAPP Computer Aided Process Planning

Overview
(Author: N. Mohan Raj, Chennai)
Introduction:
This White paper explains briefly on the standard value calculation via CAPP. Basically, CAPP is
one of the master data element in Production planning module.
Main objective of the document is to explain the basic concept of CAPP with Business
examples as well as sap Process flow. Best attempt has been made to explain key settings,
advantages, Disadvantages & Limitations of CAPP. I would also update versions based on
feedback and comments of SDN experts and consultants on this topic accordingly in future.
CAPP can be carried out for Discrete Manufacturing or PP-PI or REM. However this document
limits to Discrete Manufacturing only.

Applies to:

ECC 6.0, Sap R/3 4.6

Need for Computer Aided Process Planning:

Standard values are used in scheduling, capacity planning and costing to determine dates,
capacity requirements and costs. Standard values can be determined in several ways:

conventional procedure for determining times (for example, time studies,

estimating, polling)

sampling and statistical procedures for determining times (for example, period
time sheets)

calculation methods (for example, MTM, WF and planned times)

In contrast to the procedures listed above, CAPP is a mathematical procedure using
formulas and methods.
Structure of standard value calculation via CAPP follows below sequence

Work center (Tech data) >>>> Processes >>>>Methods >>>>Formula

Basics of CAPP elements:

Characteristics and tables serve as the basis for calculating standard values with CAPP.
They are used in CAPP elements.

A characteristic describes any detail or feature of an object, such as the length of a

screw or the depth of a casing. Characteristics are used in formulas for calculating standard
values. They are also used in classification.
Data in tables can be used calculating standard values. Tables consist of key
fields (for example, plant and work center) and one or more values in the function
section of the table, which refer to the key fields. Tables are classified as General Tables,
Table for Work center, Matrix Table and Database Table.
Note: This document covers only characteristic based calculation for ease understanding
purpose.

Business scenario:
Let us take a simple Business scenario in a company. For a new product, company has
commissioned a new drilling machine (work center). So Product routing will have drilling
operation which will be carried out in the new drilling machine. Company requested to do
standard value calculation via CAPP method for setup and Machining and also needs to be
updated in Routing using Engineering formula.
Calculation sample from Engineering:

1.
Setup time = Basic time + ( Number of Tools * variable time ) with 10%
Excess factor
So Final setup time formula = (Basic time + (Number of tools *variable time)) * 1.1
Ex: Set up time = (10 + (2 *5)) * 1.1 = 22 min

2.

Machining time = ( Number of drillings * Drill depth )/ drill speed

Ex: Machining Time = (6 * 4) / 8 = 3 min

Let us do standard value calculation via CAPP method
Sap Process Flow of CAPP:

A. Configuration:
A.1 Work center Setting:
IMG path:
Production --> Basic data --> work center --> setup work center sequence
Activate Technical data tab for work center category say 0001

A.2 CAPP specific Setting:

IMG path:
Production --> Basic data --> capp --> Define sort string, value type, machine
type, planner group, control parameters
Purpose: CAPP specific configuration
a.Sortstring & Machine Type ( Information purpose only ) :

b.Value Type ( Mapping of value type to Standard value parameter Important one ) :

c.Planner group :

d.Control Parameter

( Defining increment and calculation Type ) :

Pre requisite:

All formula characteristics must be predefined in CT04

Unit and decimal, format has to be taken care.

Master Data:
1. CAPP Formula (Tcode: CE11):
Create Engineering Formula as per requirement for both setup & Machining. Refer below

Set up CAPPTEST; Machining CAPPMACH

Example : Formula - capptest ,status - 1 (active )
Formula ( 3 lines will be there )
(Basic time + (Tools * var time )) * 1.1 .
Please note Basic time , tools , var time are defined as char already .

2. Method (Tcode: CE21)

Create a calculation method to link Formula and valuation type configured.
Note:
capptest method will have CAPPTEST formula & cappmach method will have its formula
Keep method status as active (1)

3. Processes (Tcode: CE31):

Now create process which will link method or methods.
Note:

Each process has allocated with method ( CAPPTEST PROCESS >>>CAPPTEST

METHOD )

Also , activate process status to 1

4. Work center Technology view (CR01 / CR02)

Create or Update work center (CAPP01) with Technical data in Technology tab
Additional values or rounding is not mandatory
No of Processes must be minimum 1. For initial setup , assign process as defined

below

After assignment of processes , click consistency check. There should not be any error .

5. Routing (Tcode: CA01)

Now create routing for the material and assign above work center CAPP01

Check operation details You will find setup or machine std value is blank

initially

Execution of Capp :

CAPP execution has to be done step by step as below

1.
Simulation
2.
CAPP calculation Routing & Updation
3.
Production order or planned order creation with CAPP calculation
Let us illustrate steps in details

1. Simulation:
Main Purpose of simulation is to verify and validate CAPP formula, method, process and its
calculation are correct and in sync.
This is to ensure standard value calculation for either machine time or setup time or any time
is being done @ work center as per engineering calculation

Tcode: CE41

Enter plant , work center ,process & method for simulation

Enter dummy or trial values in the fields and click next screen

Result of simulation will be populated and click next screen

Final sub calculation is shown below

Note: same can be repeated for other formula

2. CAPP calculation Routing & Updation:

Tcode: CA02
Change routing: select operation and click Extras > capp manual selection

System will show processes assigned to work center. Select all processes and click next screen

Enter expected values for calculation and click to next screen till end

Repeat for another formula also

Finally, you will get message Last selected process xxxx has been completed and save it as
below

Result:
Now check operation in routing where you find values of setup and machine
updatedautomatically .
Also , you can note calculation type and year calculated is also updated for
Referance under "determination of std values"

3. Production order or planned order creation with CAPP calculation:

Scenario 1: No Link to Production order:

If you dont want to recalculate standard values again during production order creation,
keep capp order as blank in Routing header. In simple words, standard values available
in routing operation will be retained in production order

Create production order

Check standard values Tab in operation. CAPP values in Routing is copied without any change

Scenario 2: Link to Production order:

If in case you want to change standard values while creating production order due to any
reason , then link between routing to production order has to be established . This means,
when order is created, system will propose standard values with fields for user to change and
save new value in order
Master data setup for linkage change Routing header > CAPP ORDER Field as 2 as
below

Now create production order via co01, system will pop up screen with current standard values .

Let user change values as below

Number of drillings from 8 to 10, depth from 5 to 6

Go to next screen, system proposes result based on new values as below

Same can be done for another formula also with new values if needed .

Final summary of result is shown.

Now click back screen to order and save order

Result:
1.

Refer system status - CAPP which means std values calculated via CAPP

Check Standard values in operation which shows new calculated values

*** CAPP calculation which is carried out for the order above will not change routing master
values.
This concludes the complete cycle of CAPP scenario in PP.

Key Points summary:

CAPP calculation of standard values can be done for Routing or Ref operation set
Standard values calculation can be done automatically if process & method marked
standard indicator.
Capp calculation can be done for variant configuration also for operation
If SVK is missing in work center , standard values calculation cannot be carried out
Sub operation standard values can also be calculated.
You cannot calculate value types for standard values if it was specified in the work
center that they must not or should not be entered
If the base quantity of the operation deviates from that of the method, then the method
result calculated is converted to the base quantity of the operation during a standard value
calculation.

Conclusion:
In General, CAPP is an excellent method for calculating standard values of each work center
during initial setup of production line. This CAPP tool can be used for initial simulation &
freezing final value by trial and Error. Computer-aided process planning is a link between
design and manufacturing in a computer-integrated manufacturing environment. Commonly
used by manufacturing engineers, CAPP can be used to develop a product manufacturing plan
based on projected variables such as cost, lead times, equipment availability, production
volumes, potential material substitution routings and testing requirements.
However, usage of CAPP tool in sap looks very limited or might be not explored by customer in
big way . Still reason is unknown!!!
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C
omments

3 Comments

Naresh Patil 18-Apr-2014 13:05

Hi Mohan,
Good document and well explained. Keep sharing
Regards,
Narresh
Like (0)

Mr Raheel Ahmed 10-Jun-2014 08:54

Dear Mohan Raj,

Great Effort..much appreciated ! keep sharing
Regards
Engr. Qazi Raheel Ahmed
Like (0)


Sahil Bhardwaj 10-Jun-2014 13:48

Hello Mohan,
Thanks for sharing the document, very informative