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Title PP Master Data

Version 1.0

Author Anupam Sharma

Reviewed By

Date 09.08.2011

T r a n s f o r m i n g E n t e r p r i s e s

Consulting



Project XXXX

Copyright © 2011 JKT Page 2 of 8

1. QUALITY CHECK ................................................................................................................ 3

2. BLUEPRINT AGREEMENT ................................................................................................. 3

3. LEGEND ................................................................................................................................. 3

4. OVERVIEW: MASTER DATA .............................................................................................. 4

4.1 Material Master ................................................................................................................ 4

4.1.1 Business Process Details ................................................................................................................ 5 4.2 Bill of Material ................................................................................................................. 5

4.2.1 Business Process Details ............................................................................................................ 6

4.3 Resource/Work centre ...................................................................................................... 6

4.3.1 Business Process Details.............................................................................................................. 7

4.4 Master Recipe: ................................................................................................................... 7

4.4.1 Business Process Details............................................................................................................. 7

4.5 Production version .............................................................................................................. 7



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1. QUALITY CHECK

Version Date Validated by Date Signature

1.0

2. BLUEPRINT AGREEMENT

Signing this document records your agreement to the contents of the Blueprint, and confirms thatthe remainder of the project can proceed.

Name Position Date Signature

3. LEGEND



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The following describes the symbols used in the process map:

High-level processactivity. A moredetailed process mapis provided in the

document to describethe activity

Decision

Activity step Document

System

Continuation of the

process map to adifferent page

4. OVERVIEW: MASTER DATA

4.1 Material Master

This master data helps to identify the materials that are used in Production Planningand Execution. All materials that are either produced or consumed in production



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process will be activated for MRP and Shop Floor control and relevant data shouldbe entered based on the material type.

4.1.1 Business Process Details

All materials that are taking part in the production process, Production Planning datafor the materials should be maintained and relevant Material Requirements PlanningType, Planning Strategy group etc are to be defined in the Material Master.

The MRP view of the material master primarily contains the control parameters thatgovern the material requirement planning throughout the logistics supply chain.

In the material master, MRP views contain various information like MRP Type (Typeof Planning i.e. MRP, Reorder Point Planning etc.), MRP Controller (PersonResponsible for Planning), Lot Sizing Procedure (Process to determine the Qty. ofMaterial to be Produced or Procured), Procurement Type (Internal or Externalprocurement), Scheduling data (For Rough Cut Scheduling), Planning Strategy(which govern Production Process), Availability Check controls, Dependentrequirement calculation procedure etc. The work Scheduling view of the Materialmaster data contains Shop Floor Control parameters, Production Tolerances and Lotsize dependent & Lot Size Independent In-house production time.

All Production Planning data is maintained at the plant level. This allows controllingthe PP processes for the plant of a company in different ways.

PP-specific data in the material master plays a part in:

Managing MRP information for materials

Managing Production Controls for materials

Planning for Procurement proposals and Planning Strategy

To control PP activities following data are defined

· MRP Data

MRP Type

MRP ControllerLot Sizing Procedure

Procurement Type

Scheduling Margin Key

Planning Strategy Group

Availability Check Control

· Work Scheduling Data

Delivery tolerances

Lot-Size Dependent In-House production time

Lot-Size Independent In-House production time

Production Scheduler

4.2 Bill of Material

A bill of material is a complete, formally structured list of the components that make up a productor assembly. The list contains the object number of each component, together with the quantityand unit of measure.



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BOM s are used in their different forms in various situations where a finished productis assembled from several component parts or materials. Depending on the industrysector, they can also be called material list or lists of ingredients and so on. Theycontain important basic data for numerous areas of a company, for example:

MRP (Material requirements Planning)

Material provisions for production

Product costing

Plant Maintenance

Structure of a BOM:

The data stored in bills of material serves as a basis for production planning activities such as:

A design department can base its work on bills of material.

A material requirements planning (MRP) department explodes bills of material on

a certain date to calculate cost-effective order quantities for materials.A work scheduling department uses bills of material as a basis for operationplanning and production control.

A production order management department uses bills of material to plan theprovision of materials.

The data stored in bills of material is also used in other activities in a company such as:

Reservation and goods issue : As an aid to data entry

Product costing : To calculate the costs of materials required for a specific product

4.3 Resource/Work centre

This master data helps to identify the production centers that are used in ProductionPlanning and Execution. This master data is used in Master recipe andProduction/Process orders to identify which machines / production centers are being

used in manufacturing the materials attached in the Master recipe / Production(Process ) order.

The commonly work centers/resources in cement industry are as follows:

S NO. RESOURCE/WORK CENTRE CODING

1 CRUSHER2 RAW MILL3 KILN4 GRINDING MILL



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5 BLENDER6 COAL MILL7 PACKAGING STATION8 CLASSIFIER


A Resource is an organizational unit where a work step is carried out, producing anoutput.Data in resource is used for :

Scheduling: Operating times and formulas are entered in theresource, so that the duration of an operation can be calculated.Capacity Planning: The available capacity and formulas forcalculating capacity requirements are entered in the resource Costing: Formulas are entered in the resource, so that the costsof an operation can be calculated. A resource is also assigned toa cost centre.Capacity Requirements Planning : Formulas for calculatingcapacity requirements for an operation are maintained inresourceSimplification of Operation Maintenance: Various defaultvalues like Control key, Standard Values etc. are maintained forthe operation in the resource.

4.4 Master Recipe:

A master recipe is a description of which operations (process steps) have to becarried out and in which sequence to produce a material (product). In addition to the informationabout the operations and the sequence in which they are carried out, a master recipe alsocontains details about the resource at which they are carried out and the components required ateach step.


A master recipe is used as a source for creating a production order by copying. A masterrecipe is composed of a header and one or more operations. The header contains datathat is valid for the whole master recipe. A sequence is a series of operations. Operationsdescribe individual process steps, which are carried out during production. A masterrecipe is identified by its group and group counter .

A master recipe is used to produce output materials (finished, semi finishedproducts). It contains operations and data on the corresponding work centers,material allocations, operation texts and standard values for operations. In the SAPSystem, master recipes have the same basic structure as master recipes, inspectionplans, maintenance task lists. As a generic term for these objects, SAP hasintroduced the term "task list".

A master recipe is created in order to produce substances on a plant line. A masterrecipe

Describes the activities necessary for productionAllocates resource and materials to the master recipe

4.5 Production version

Production version represents the combination of master recipe & BOM can becreated if required. Many of the Products are having an alternate BOM and in somecases alternate master recipe too.



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In this case it is mandatory to have production version maintained so that at the time oforder creation, user can select the suitable production version so that the relevant BOMand master recipe gets copied in to the order..

It is a prerequisite to create production versions for products, i.e. combination of BOM &Master recipe.

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