Production planning- Process Industry

Configuration

1. Create Order Type for Process Order using Tcode CORN

Process Order Type: PI01

Enter order category as 40 (process order) and order type as PI01 and save the order type

2. Create Order Type Dependent Parameters using Tcode COR4

Assign Order type PI01 to plant 1000 and save the order dependent parameters
3. Create Production Scheduling Profile using Tcode CORY

In ‘Automatic actions’ on release select all the three functions and save production scheduling
profile
4. Specify Scheduling Parameter using Tcode OPUZ

Create scheduling parameters as per requirement

5. Specify confirmation Parameter for order type PI01
6. Create Control Recipe Destination using Tcode O10C

Control recipe destination is a Process control system, line operator, or group of line operators
that receives

and executes control recipes.

Control Recipe destination: G2

Enter plant, control recipe destination, destination type as 4 (browser based PI sheets) and
address of

operator and save the destination

7. Copy standard characteristics and message categories to the client

Execute adopt predefined characteristics, adopt predefined message categories and adopt
predefined display

variants
8. Create characteristics for process messages and process instructions using Tcode O27C

Enter description, characteristics group as process message characteristics or process

instruction characteristics.

Also enter data type, number of char, number of decimals and unit of measure and save the
characteristic
9. Create Process Massage Destination using Tcode O03C

Process Message destination: PL01

Process massage destination is a User or component to which process messages are sent for
processing.

Enter destination name, Type and destination address and save

10. Create process message categories using Tcode O13C

Process message category: K001

Enter process message category and its description and double click on
‘characteristics/message categories’

and then assign the required characteristics

Now double click on destinations/message categories and enter the process message
destination previously

created

11. Create Process Instruction Category using Tcode O12C

Enter instruction category name, description and process instruction category type
Process instruction category: A001, Process instruction type: 1 (Process parameters)

Double click characteristics/process instruction categories and enter required characteristics and
its values which will get displayed in PI sheet as process parameters

Now create second category K001 with category type as 2 (Process data request) and double
click on characteristics/process instruction categories.
Enter required characteristics as well as predefined characteristics and their values as below and
save the characteristics.

In PI sheet, the process instruction destination has to fill this data and send it to the process
message destination

Master Data

1. Create finished product and its raw materials using Tcode MM01

Finished product: ICE CANDY1 Raw Materials: 7000000116, 7000000117

On ‘work scheduling’ view of finished product, enter production scheduling profile as G001 and
save the material

2. Create finished product BOM using Tcode CS01

Enter the ingredients and quantity in which they are required and save the BOM

3. Create Resource using Tcode CRC1

 Resource: MIXER

4. Create Master Recipe using Tcode C201

In recipe header enter status and usage and the go to ‘Operation’ tab
Enter Phases and operations with required resource and control key also enter the process
instruction destination.
Now save the master recipe and again go to change master recipe using Tcode C202 and then
go to ‘Material’ tab

In production version enter ‘alternative BOM’ and ‘BOM usage’ and select ‘Check’, system will
automatically pic the correct BOM.

Now go to ‘operation’ tab and select phase to which the process instructions are to be assigned
and then

select
For auto goods issue and auto goods receipt select last phase and go to process instructions tab
and assign standard process instructions PROD_5 (auto goods receipt) and CONS_5 (goods
issue), assign CONS_5 two times as there are two ingredients that needed to do goods issue.

Now double click on CONS_5 and assign ingredient number and its base unit of measure to
respective characteristics, repeat same for other ingredient.

Now select Go To- Process management- simulate PI sheet for control recipe destination
System will show the simulation of PI sheet which will be sent to control recipe destination

Phase: 0020

Phase: 0040
Phase: 0080

Now save the control recipe

Business process steps

1. Create Process Order Manual using Tcode COR1

Enter required quantity and release the order

Once release is carried out, the system will give the message

as

As it’s mentioned in production scheduling profile that generate control recipe at the order
release, now save The order.

2. Order confirmation using Tcode COR6N

Enter the order number and phase no. and save the confirmation, similarly do the confirmation of
all the phases.
2. Control recipe monitor using Tcode CO53

Select ‘created/sent’ tab to access generated control recipe

Now select the control recipe and select ‘Send’ to send the recipe to control recipe destination

The system will give message as

3. Maintain PI Sheet using Tcode CO55/CO60

Select the PI sheet and select

Enter the actual values of process parameters that is speed, temperature and viscocity

Enter quantity of finished material to do goods receipt and quantities of raw materials to post
goods issue

Now select ‘complete’ to complete the document and generate process messages

4. Process message monitor using Tcode CO54

Select ‘To Be Sent’ tab to view and edit the process messages

PI_CRST: Process message to change status of control recipe to ‘Executed’

K001: Process message of actual readings of process parameters

PI_PROD: Process message for goods receipt of finished product

PI_CONS: Process message for goods issue of raw materials

Now first to post the goods issue select the PI_CONS message and select
Here enter the storage location in front of characteristic PPPI_STORAGE_LOCATION and save

Now select both PI_CONS messages and select to send the messages at process
message destinations.
Similarly enter storage location in PI_PROD message and send the message to post goods
receipt,

Also check the process parameters and send K001 message to message destination, which is of
SAP user type, this will trigger mail to the address mentioned.

After that send PI_CRST message which will change the status of control recipe to completed.

5. Check the status of control recipe using Tcode CO53

Status of control recipe is ‘Executed’

6. Check good issue and goods receipt documents using Tcode MB51

1. Raw material: 7000000116

2. Raw material: 7000000116

3. Finished product: ICE CANDY1

7. Technical completion of order and order settlement using Tcode KO88

Enter controlling area, order number and settlement period and execute
Resource Classification in Master Recipe
for Planning
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Often, many industries like FMGC, chemical, pharmaceutical, etc use multiple similar
resources to manufacture a product.

E.g. A plant has many mfg bagger, or filling lines with identical capacities. A product is
chronologically said to be manufactured in bagger 2. Alternatively this product also can be
manufactured in bagger 3 or bagger 4 if needed. On shop-floor business cannot determine
the primary resource to be used until shortly before order processing. But in mid to long
term planning, they want to assign a suitable planning resource to the operations
provisionally.
The constraint for long term planning needs to be on planning resource. In short term the
flexibility needs to be given for resource selection based on SKU. This can be mapped in
different ways in SAP.

1. By multiple production Versions with multiple master recipe

This method is most widely used but requires laborious master data maitainance as one
recipe has to be created explicitly for each resource and has to be assigned to one
production version respectively.

2. By manual selection in the Order.

The resource is changed manually on the Order. This change requires a single approval
process if ECM to be used. Production Planners will feel as more work and any change which
needs a Quality Approval in GMP environments will take more time to create and release
the order for production.

3. By Resource Selection through classification.

SAP provides another way of maintaining this alternate resource selection by using resource
classification.

We can use a planning resource as the primary resource and select the alternate resource
through the resource network maintained through work center classification (type 019).
This also works well with ECM and is a good option for Planners as there is no need of Single
Approval from QA personnel.

Create a Characteristic (T-Code CT04)

We can create classifications in ECC for suboperations and secondary resources.

In Additional data tap define Table Name as CRHD and Field Name as ARBPL.

Create Class and assign characteristics to class T Code: CL02

Assign classification in ressource T Code: CRC1 or CRC2

All relevant alternative work centers must contain exactly the same classification and
characteristic value assignment. Work centers with different classes or characteristic values
are ignored.
Assign the classification in master recipe and add alternate resources T Code: C201 or
C202
Create process order COR1 or By MRP Planned order to Process order

On the operations tab, select the operation 10 and click on Resource selection condition
Product can be produced on all 3 lines here you can select the resource accordingly.

Capacity Planning CM25

We can change the resource from this screen by dragging and dropping it to another resource from
the resource section.

Resource classification automatically creates multiple modes in APO PDS or PPM, so it can
be used in PPDS while converting SNP Plan orders to PPDS plan orders. And in DS board we
can schedule the order on required resource.
If we want to use different capacities for planning, but for execution purpose we only want
to use one resource. So from many lines in mid term planning to accommodate constraints,
but for short term we use single resource for production execution.